CN107529852B

CN107529852B - Article of footwear including a sole member having a geometric pattern

Info

Publication number: CN107529852B
Application number: CN201680022473.9A
Authority: CN
Inventors: 沙恩·S·科哈楚; 克利斯多佛·S·库克; 布雷特·斯顾梅斯特
Original assignee: Nike Inc
Current assignee: Nike Inc
Priority date: 2015-05-27
Filing date: 2016-05-12
Publication date: 2021-01-08
Anticipated expiration: 2036-05-12
Also published as: US20190116930A1; US11553756B2; EP3302135B1; US10973280B2; WO2016191108A1; CN107529852A; US20210195997A1; EP3302135A1; US20230122676A1; US10206456B2; US20160345667A1; EP3861879A1

Abstract

An article of footwear (2600) includes an upper (2602) and a sole structure (2610) having a sole member. The sole member may include a collection of apertures (150) formed along various surfaces of the sole member. The sole member may be manufactured using a customized cushioning sole system, forming a generally circular pattern throughout the sole member. The foot morphology and/or preferences of the user may be used to design the sole member.

Description

Article of footwear including a sole member having a geometric pattern

Technical Field

Background

The present embodiments relate generally to articles of footwear, and in particular, to articles having cushioning arrangements and methods of manufacturing such articles.

Articles of footwear generally include two primary elements: an upper and a sole structure. The upper is generally formed from a plurality of material elements (e.g., textiles, polymer sheet layers, foam layers, leather, synthetic leather) that are stitched or adhesively bonded together to form a void on the interior of the footwear for comfortably and securely receiving a foot. More specifically, the upper forms a structure that extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. The upper may also incorporate a lacing system to adjust the fit of the shoe, as well as to permit entry and removal of the foot from the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability and comfort of the footwear, and the upper may incorporate a heel counter.

The sole structure is secured to a lower portion of the upper so as to be positioned between the foot and the ground. For example, in athletic footwear, the sole structure includes a midsole and an outsole. Various sole structure components may be formed from polymer foam materials that attenuate ground reaction forces (i.e., provide cushioning) during walking, running, and other ambulatory activities. For example, the sole structure may also include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motion of the foot.

Disclosure of Invention

In one aspect, the present disclosure is directed to a sole member for an article of footwear that includes a sole member that includes an outer surface, and the outer surface includes an upper surface and a lower surface. Further, the sole member has an interior portion, wherein the interior portion is disposed between the upper surface and the lower surface. The sole member includes at least a first set of apertures, wherein at least one aperture of the apertures of the first set of apertures is a blind aperture. The first set of apertures is disposed along a portion of the outer surface of the sole member, and each aperture of the first set of apertures has a length that extends through a portion of the interior portion of the sole member. The first set of apertures are arranged in a first substantially circular pattern along an outer surface of the sole member.

In another aspect, the present disclosure is directed to a sole member for an article of footwear that includes a sole member that includes an outer surface, and the outer surface includes an upper surface and a lower surface. The sole member has at least a first set of apertures, wherein at least one of the first set of apertures is a blind aperture. The first set of apertures is disposed along a portion of the outer surface of the sole member to form a generally circular first pattern, and each aperture of the first set of apertures is disposed at a first radial distance from a center of the first pattern.

In another aspect, the present disclosure is directed to a method of customizing a cushioning sole system for an article of footwear, the method comprising obtaining information about a pressure distribution of a foot of a wearer, and generating a first pattern comprising a first set of apertures disposed about a center of the first pattern. The method further includes generating instructions to form a first pattern in the sole member, and executing the instructions to form a first set of apertures in the sole member, wherein each aperture of the first set of apertures is disposed at a first radial distance from the center.

Other systems, methods, features and advantages of the present embodiments will be or become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the accompanying claims.

Drawings

Embodiments may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 is an isometric view of an embodiment of a cushioning element including an aperture;

FIG. 2 is an isometric view of an embodiment of a cushioning element including an aperture;

FIG. 3 is an isometric view of an embodiment of a cushioning element including an aperture;

FIG. 4 is an isometric bottom view of an embodiment of a sole member including a cushioning element;

FIG. 5 is an isometric view of an embodiment of a cushioning element in an unloaded state including an aperture;

FIG. 6 is an isometric view of an embodiment of a cushioning element undergoing deformation including an aperture;

FIG. 7 is an isometric bottom view of an embodiment of a sole member including a cushioning element;

FIG. 8 is an isometric view of an embodiment of a cushioning element in an unloaded state including an aperture;

FIG. 9 is an isometric view of an embodiment of a cushioning element undergoing deformation including an aperture;

FIG. 10 is an isometric view of an embodiment of a hole pattern;

FIG. 11 is an isometric view of an embodiment of a hole pattern;

FIG. 12 is an isometric view of an embodiment of a hole pattern;

FIG. 13 is an isometric view of an embodiment of a hole pattern;

FIG. 14 is an isometric view of an embodiment of an aperture pattern;

FIG. 15 is an isometric view of an embodiment of a hole pattern;

FIG. 16 is an isometric view of an embodiment of an aperture pattern;

FIG. 17 is an isometric view of an embodiment of an aperture pattern;

FIG. 18 is an isometric view of an embodiment of a hole pattern;

FIG. 19 is an isometric view of an embodiment of a hole pattern;

FIG. 20 illustrates an embodiment of the use of an apparatus for obtaining three-dimensional foot data;

FIG. 21 schematically illustrates an embodiment of a virtual image of digitized three-dimensional foot data;

FIG. 22 schematically illustrates an embodiment of a virtual image of a template for a sole structure;

FIG. 23 schematically illustrates an embodiment of a virtual image of a customized sole structure;

FIG. 24 is an isometric view of an embodiment of a sole member during the process of forming an aperture;

FIG. 25 is an embodiment of an influence graph;

FIG. 26 is an isometric bottom view of an embodiment of an article of footwear with a sole member; and

FIG. 27 is an embodiment of a flow chart of a method of manufacturing a customized sole member.

Detailed Description

Fig. 1-3 depict different embodiments of a portion of a cushioning element. The cushioning element may include provisions for increasing flexibility, fit, comfort, and/or stability during deformation or use of the cushioning element or an article incorporating the cushioning element. Some of the embodiments of cushioning elements as disclosed herein may be used in various articles of apparel. In one embodiment, the cushioning element may be used in an article of footwear. For example, as discussed in further detail below, in one embodiment, portions of the sole structure or sole member may incorporate or otherwise include cushioning elements.

Directional adjectives are also employed throughout the detailed description corresponding to the illustrated embodiments for consistency and convenience. The term "lateral" or "lateral direction" as used throughout the detailed description and claims refers to a direction extending along the width of a component or element. For example, the lateral direction may be oriented along a lateral axis 190 (see fig. 20) of the foot, which may extend between the medial and lateral sides of the foot. Additionally, the terms "longitudinal" or "longitudinal direction" as used throughout the specification and claims refer to a direction extending across the length of an element or component (such as a sole member). For example, the longitudinal direction may be oriented along a longitudinal axis 180 that may extend from a forefoot region to a heel region of the foot (see fig. 20). It should be understood that each of these directional adjectives may also apply to various components of an article of footwear, such as an upper and/or a sole member. Additionally, vertical axis 170 refers to an axis perpendicular to a horizontal surface defined by longitudinal axis 180 and lateral axis 190.

Fig. 1 depicts an embodiment of a first cushioning element ("first element") 100, fig. 2 depicts an embodiment of a second cushioning element ("second element") 200, and fig. 3 depicts an embodiment of a third cushioning element ("third element") 300. As shown in fig. 1-3, in some embodiments, the cushioning element may include one or more apertures 150. For purposes of illustration, the aperture 150 is an opening, hole, void, channel, or space disposed within the cushioning element. Generally, the apertures 150 are initially formed along an exterior or outer surface of the cushioning element and may extend any distance through the interior portion 199 (e.g., thickness, breadth or width) of the cushioning element in any orientation. It should be understood that the term outer surface or exterior surface with respect to the sole member does not necessarily indicate whether the sole member is actually exposed to an external element. Conversely, the outer surface or exterior surface refers to the outermost, outward-facing layer of the sole member. In some embodiments, the inner portion 199 may be disposed between the upper surface 152, the lower surface 154, and the sidewall. Throughout the specification, it should be understood that a characteristic described as being associated with a single aperture or set of apertures may also characterize any other aperture or set of apertures that may be mentioned in various embodiments.

Embodiments described herein may also include or refer to techniques, concepts, features, elements, methods, and/or components from the following patent applications: U.S. patent application No.14/722,758 entitled "Article of Footwear including a Sole Member with Apertures" (filed 5/27 of 2015); U.S. patent application No.14/722,782 entitled "Article of Footwear including a Sole Member with a pattern of apertures" (filed on 27/5/2015); and U.S. patent application No.14/722,740 entitled "Article of Footwear including a Sole Member with a pattern of areas" (filed on 27/5/2015), the entire contents of each patent application being incorporated herein by reference.

In various embodiments, the cushioning element may comprise any three-dimensional shape or geometric shape, including regular or irregular shapes. For example, the cushioning element may be substantially flat or narrow, and/or relatively thick or wide. The geometry and size of the cushioning element may be configured for the application or application in which it will be used. For illustrative purposes, in fig. 1-3, portions of the cushioning element have a generally rectangular, three-dimensional shape. Further, for reference purposes, as shown in fig. 1-3, each cushioning element may include an upper surface 152 and a lower surface 154 disposed opposite the upper surface 152. In some cases, the upper surface 152 can be disposed adjacent to or in engagement with another component, such as an upper (see fig. 26). Further, in some cases, the lower surface 154 may be a ground-contacting surface. In other cases, however, lower surface 154 may be disposed adjacent another material (such as an outsole). The cushioning element may further include additional outwardly facing surfaces. For example, as shown in fig. 1-3, cushioning element has four sidewalls that include a first side 156, a second side 157, a third side 158, and a fourth side 159. First side 156, second side 157, third side 158, and fourth side 159 may extend between upper surface 152 and lower surface 154. Additionally, cushioning element includes a thickness 140 extending between upper surface 152 and lower surface 154 along a vertical axis 170, and a width 146 extending from second side 157 to fourth side 159 along a lateral axis 190, and a length 148 extending from first side 156 to third side 158 along a longitudinal axis 180. As shown in fig. 1, thickness 140 may include an upper portion 182 and a lower portion 184. The width 146 may include a front portion 192 and a rear portion 194. Further, length 148 may include a first side portion 186 and a second side portion 188. The upper surface 152, lower surface 154, and sidewalls as depicted herein are associated with the outer surface of the cushioning element.

It should be understood that other embodiments may have a fewer or greater number of exterior surfaces, and that the cushioning elements and the different regions of the cushioning elements shown herein are for illustrative purposes only. In other embodiments, the cushioning element may include any profile and may be any size, shape, thickness, or size, including regular and irregular shapes.

In some embodiments, the aperture 150 has a circular shape. In other embodiments, the apertures 150 may comprise a wide variety of other geometric shapes, including regular and irregular shapes. For example, the aperture 150 may have a cross-sectional shape that is circular, square, or triangular. In some embodiments, apertures 150 may have various geometries that may be selected to impart particular aesthetic or functional properties to the cushioning element. In one embodiment, the aperture 150 may comprise a void having a substantially cylindrical shape. In some embodiments, the cross-sectional diameter of the bore may be substantially uniform or uniform throughout the length of the bore.

In some cases, the aperture 150 may be disposed on or through the lower surface 154 or the upper surface 152 of the cushioning element. In other cases, the aperture 150 may be disposed on or through a side surface of the cushioning element. In one embodiment, apertures 150 may be disposed on or through a side surface of cushioning element (e.g., along first side 156, second side 157, third side 158, and/or fourth side 159), and may be disposed on lower surface 154 and upper surface 152 of cushioning element.

In some embodiments, the apertures 150 may provide a means for separating or softening portions of the cushioning element in order to enhance its cushioning characteristics. For purposes of this disclosure, cushioning properties refer to the fit, flexibility, cushioning, responsiveness, comfort, resilience, shock absorption, elasticity, and/or stability present in a portion of an element. For example, in some cases, apertures 150 may be formed in side and lower portions of the cushioning element to reduce the cross-sectional profile of the element at particular regions and/or to promote increased flexibility between various portions of the element. In one embodiment, the apertures 150 may be applied to the side portions and the upper portion to form regions between adjacent portions of the elements that articulate or bend relative to one another.

Thus, in this embodiment, operation of the cushioning element may involve providing a material differential for the element. The material differentiation may be achieved by providing voids (holes) that may include cuts through the cushioning element. As will be described below with respect to fig. 25, the cut-out may involve removing material from the element, thereby providing a softer and/or cushioned region in the portion that includes the aperture.

In general, apertures 150 may include various openings or voids arranged in various orientations and in various locations on or through the cushioning element. For example, as shown in fig. 1, in some embodiments, the first set of apertures 102 may include an aperture 150, the aperture 150 extending through the thickness 140 of the first element 100 in a direction generally aligned with the vertical axis 170. In the first cross-section 104 of the first element 100 of fig. 1, it can be seen that the apertures of the first set of apertures 102 start along the lower surface 154 and extend towards the upper surface 152. Thus, the apertures 150 of the first set of apertures 102 include a series of openings 142 (i.e., gaps or openings) along the exterior surface of the first element 100. In fig. 1, the lower surface 154 includes an outer surface in which the opening 142 (shown here as partially formed in the first section 104) is formed. As will be discussed further below, the apertures 150 may extend from the initial void along the outer surface to form apertures of varying sizes and lengths through the thickness 140 of the cushioning element. In some embodiments, the holes 150 may be blind holes, wherein only one end of each hole is open or exposed, while the opposite end of each hole remains enclosed within the thickness of the element (i.e., only one end of each hole may be exposed on the exterior surface of the element).

Further, in fig. 2, it can be seen that in another embodiment, there may be a second set of apertures 202, the second set of apertures 202 including the aperture 150, the aperture 150 extending through the thickness 140 of the second element 200 in a direction generally aligned with the vertical axis 170. In a second cross-section 204 of the second element 200 of fig. 2, the holes of the second set of holes 202 are formed along the upper surface 152 and extend towards the lower surface 154. Further, in FIG. 2, it can be seen that an opening 142 including exposed ends of the aperture 150 is disposed along the upper surface 152.

It should also be understood that in some embodiments of the cushioning element, there may be apertures 150 formed along multiple surfaces. For example, in fig. 3, third hole set 302 includes holes 150, holes 150 extending through thickness 140 of third element 300 in a direction generally aligned with vertical axis 170. However, in this embodiment, as shown in third cross-section 304, third set of apertures 302 includes apertures 150 having openings 142 formed along both lower surface 154 and upper surface 152. Thus, third hole set 302 includes an upper set 324 and a lower set 326. The apertures 150 including the upper set 324 extend from the upper surface 152 toward the lower surface 154, and the apertures 150 including the lower set 326 extend from the lower surface 154 toward the upper surface 152.

In different embodiments, the number of apertures 150 comprising each set of apertures may vary. For example, in one embodiment, the first set of apertures 102 may include between 1 and 100 apertures, or more than 100 apertures. In another embodiment, the first set of apertures 102 may include between 40 and 70 apertures. In other embodiments, the second set of apertures 202 may include more than 100 apertures. Further, in some embodiments, the second set of apertures 202 may include between 1 and 30 apertures. In other embodiments, the second set of apertures 202 may include more than 30 apertures. Similarly, in some embodiments, third hole set 302 may include various numbers of holes 150. Thus, depending on the cushioning characteristics desired, there may be more apertures or fewer apertures than shown in any set of apertures formed in a portion of the cushioning element.

As described above, in some embodiments, the apertures 150 may extend various distances through the cushioning element. For example, as shown in fig. 1, some of the apertures 150 of the first set of apertures 102 may not extend above the lower portion 184 of the first element 100. However, other apertures 150 may extend further upward above the lower portion 184 and into the upper portion 182. Likewise, in some cases, the apertures 150 of the second set of apertures 202 may be disposed only in the upper portion 182, while other apertures 150 may extend further downward. For example, the aperture may extend from the upper surface 152 and be at least partially disposed within the lower portion 184. It should be understood that the various parts may differ from those shown herein and are for reference only. Thus, the aperture 150 may comprise any length (including diagonal lengths) from zero to several full lengths, widths, or heights of the cushioning element. Where the geometry of the cushioning elements varies from the generally rectangular shape shown in fig. 1-3, the apertures may be formed such that they extend upwardly to a maximum length, thickness, breadth or width associated with the cushioning elements. Thus, in some embodiments, the length of each aperture may vary with the size or dimensions of the cushioning element.

Generally, the shape of one or more apertures 150 in the cushioning element may vary. In some cases, one or more of the apertures 150 may have a linear configuration or shape. In other cases, one or more of the apertures 150 may have a non-linear configuration or shape. For example, in the embodiment of fig. 1-3, the illustrated aperture 150 has a substantially linear shape.

In different embodiments, the size of the one or more apertures 150 relative to each other may vary. For example, referring to fig. 1, in some embodiments, the length of each aperture in the first set of apertures 102 may vary. For example, in one embodiment, the apertures 150 of the first set of apertures 102 may be longer than the other apertures 150 of the first set of apertures 102. Thus, in fig. 1, the first hole 110 has a shorter length than the adjacent second hole 112. However, in other cases, the length of each aperture in the first set of apertures 102 may vary in another manner. For example, the length of the first aperture 110 may be substantially similar to or greater than the length of the second aperture 112. Thus, the length of each aperture may be different from the length of the other apertures, and the length of apertures 150 located in different portions of the cushioning element may vary relative to one another. The length of the bore may also vary with reference to the longitudinal axis 180 and/or the lateral axis 190. Some examples of this category are described further below.

In addition, the size of each aperture may vary. For the purposes of this specification, the size of a hole may refer to the cross-sectional diameter or cross-sectional size of the hole. In some cases, the volume associated with the interior of the pores may be related to the average cross-sectional diameter of the pores. Referring to fig. 3, in some cases, each hole in third set of holes 302 may have a substantially similar size (e.g., cross-sectional diameter). In other cases, two or more apertures in third aperture set 302 may have significantly different sizes. For example, the size of the third hole 310 is smaller than the size of the adjoining fourth hole 312. However, in other cases, the size of each hole in third hole set 302 may vary in another manner. For example, the size of the third aperture 310 may be substantially similar to or larger than the size of the fourth aperture 312. Thus, the size of each aperture may be different from the size of the other apertures, and the sizes of apertures 150 located in different portions of the cushioning element may vary relative to one another. In other cases, the size of each aperture may vary with the size of the cushioning element. It should be understood that the size of the pores may vary throughout a single pore such that one region of the pore is larger or smaller than another region of the same pore. However, in other embodiments, the size of the aperture may remain substantially constant throughout the length of the aperture. Some examples of this category are described further below.

In some embodiments, the apertures on different portions of the cushioning element may be substantially parallel to each other relative to another surface or side of the element. In some cases, the holes extending from the same surface of the cushioning element may be substantially parallel to each other such that they do not intersect. In other words, the holes may be oriented in substantially similar directions. For example, the apertures formed on the lower surface 154 or the upper surface 152 may be similarly oriented in a direction generally aligned with the vertical axis 170. Thus, in different embodiments, the apertures 150 may be associated with approximately similar longitudinal, lateral, or vertical orientations. However, in other embodiments, the holes on the side surfaces may not be parallel to each other. In one example, there may be apertures having openings 142 on the first side 156 oriented in one direction and apertures having openings 142 on the first side 156 oriented in a different direction. Further, it should be appreciated that in some embodiments, only some of the apertures may be substantially aligned by upper portion 182, lower portion 184, first side portion 186, second side portion 188, front portion 192, and/or rear portion 194, while other apertures provided throughout the cushioning element may not be aligned. Thus, it should be understood that although the embodiment of fig. 1-3 shows the holes 150 having a length extending along the vertical axis 170, the holes may be oriented such that they are in any other direction (e.g., horizontal, diagonal, or non-planar). For example, in some embodiments, the holes may form an angle less than 90 degrees and greater than 0 degrees with respect to vertical axis 170, lateral axis 190, and/or longitudinal axis 180. In some cases, the holes may form an angle between 30 and 60 degrees with respect to vertical axis 170, lateral axis 190, and/or longitudinal axis 180.

The cushioning element may have a responsiveness to changes in force due to the different possible configurations that include the aperture 150. In other words, the apertures 150 may be arranged in a pattern that may help attenuate ground reaction forces and absorb energy, thereby imparting different cushioning characteristics to the element. In the embodiments of fig. 4 to 9, a sequence of images representing possible responses of the buffer element under load is shown.

Fig. 4 depicts an embodiment of first sole member 400 for the purpose of providing a contextual example to the reader. In fig. 5, a cross-section is shown in the first sole member 400 taken along line 5-5 of fig. 4, depicting a fourth element 500. Fourth element 500 has a series of holes 150 disposed along lower surface 154 and extending through thickness 140 at varying lengths. For example, the aperture 150 disposed closer to the third side 158 is longer than the aperture 150 disposed closer to the center 550 of the fourth element 500. Further, the apertures 150 disposed closer to the center 550 of the fourth element 500 are shorter than the apertures 150 disposed closer to the first side 156. In some embodiments, the apertures 150 may form a geometric pattern. In other words, the apertures 150 may be arranged such that there is a predictable rise and fall in the height of the apertures across the cushioning element. In fig. 5-6, the length of the aperture 150 decreases as the aperture 150 approaches the center 550 of the fourth element 500, and then the length of the aperture 150 increases as the aperture 150 moves further away from the center 550. The regular arrangement shown in fourth element 500 may provide a more consistent buffer for the user in some cases. However, it should be understood that in other embodiments, the apertures 150 may have a random height arrangement.

For convenience, heights may be associated with different portions of fourth element 500. In fig. 5, a first height 510, a second height 520, and a third height 530 are identified. A first height 510 is associated with the portion of fourth element 500 facing first side 156, a second height 520 is associated with the portion of fourth element 500 facing center 550, and a third height 530 is associated with the portion of fourth element 500 facing third side 158. In fig. 5, first height 510, second height 520, and third height 530 are substantially similar such that thickness 140 is substantially uniform throughout fourth element 500.

As shown in fig. 6, the arrangement of the apertures 150 may change the cushioning responsiveness of the material when the fourth element 500 is subjected to a first load 600 (represented by the arrows). In fig. 6, the first load 600 is directed downwardly in a direction generally aligned with the vertical axis 170 and is distributed in a substantially constant or uniform manner on the upper surface 152 of the fourth element 500. When the fourth element 500 is subjected to the force of the first load 600, the fourth element 500 may deform.

In some embodiments, the cushioning elements may deform in different ways when they are compressed. The deformation that occurs may be related to the location of any hole and/or the size and orientation of the hole. Thus, the apertures 150 may work together within the material of the cushioning element to provide a change in the relative stiffness, degree of ground reaction force attenuation, and energy absorption properties of the cushioning element. By the methods described herein, these cushioning characteristics can be varied to meet the specific requirements of the activity for which the cushioning element is intended.

In some embodiments, for example, when the compressive force of first load 600 is applied to fourth element 500, the region comprising more pores and/or pores of greater size or length may deform to a greater degree than portions of fourth element 500 having fewer pores and/or pores of lesser size or length. As a result of the application of the first load 600, the aperture opening may be compressed and/or deformed, as shown in fig. 6. This deformation is greater in the region closest to the third side 158 where there is a longer hole relative to the center of the fourth element 500. Similarly, the degree of deformation is greater in the region closest to the first side 156 where the apertures are longer relative to the apertures disposed near the center 550. Thus, minimal deformation of fourth element 500 occurs near center 550, where shorter or smaller apertures are present.

In some embodiments, the deformation occurring throughout fourth element 500 may be measured in part by the changing shape and height of fourth element 500 and/or the changing shape and height of aperture 150. Specifically, in fig. 6, a fourth height 610, a fifth height 620, and a sixth height 630 are identified. Fourth height 610 is associated with a portion of fourth element 500 facing first side 156, fifth height 620 is associated with a portion of fourth element 500 facing center 550 of fourth element 500, and sixth height 630 is associated with a portion of fourth element 500 facing third side 158. Referring to fig. 5 and 6, due to the first load 600, it can be seen that the fourth height 610 is less than the first height 510, the fifth height 620 is less than the second height 520, and the sixth height 630 is less than the third height 530. Further, in fig. 6, the fourth height 610, the fifth height 620, and the sixth height 630 are substantially different from one another such that the thickness 140 is substantially non-uniform throughout the fourth element 500. In other words, various profiles have been formed along the upper surface 152 to which the first load 600 has been applied. In some embodiments, the profile may vary in a manner that generally corresponds to the arrangement of the apertures 150 provided in the fourth element 500. Accordingly, fifth height 620 is greater than fourth height 610 and sixth height 630, and sixth height 630 is greater than fourth height 610.

In some embodiments, the shape or orientation of the aperture may also change as a result of the applied force. The change in area or shape may be different depending on the magnitude and direction of the force(s) applied. For example, referring to fig. 6, in one embodiment, fourth element 500 may be exposed to a force or load, whereby the aperture deforms not only by becoming more compact, but also by curling or otherwise becoming more and more non-linear and/or irregular. In one embodiment, the area or volume of the aperture may decrease when a compressive force is applied.

Similarly, compressive forces may produce responses in other types of cushioning elements. To provide a contextual example to the reader, fig. 7 depicts an embodiment of a second sole member 700. In FIG. 8, a cross-section taken along line 8-8 of FIG. 7 in the second sole member 700 depicts a fifth cushioning element ("fifth element") 800 that is unloaded. The fifth element 800 has a series of through holes 150 extending from the lower surface 154 through the thickness 140 to the upper surface 152. As described above, in some embodiments, the apertures 150 may be disposed along only some regions of the fifth element 800. In fig. 8 and 9, the fifth element 800 includes a first area 860, a second area 862, a third area 864, a fourth area 866, a fifth area 868, a sixth area 870, a seventh area 872 and an eighth area 874. First area 860, third area 864, fifth area 868, and seventh area 872 constitute portions that include aperture 150, while second area 862, fourth area 866, sixth area 870, and eighth area 874 constitute portions that do not include aperture 150.

As shown in fig. 9, the arrangement of apertures 150 may change the cushioning responsiveness of the material when second sole member 700 and/or fifth element 800 are subjected to a second load 900 (represented by the arrows). In fig. 9, the second load 900 is directed downwardly in a direction generally aligned with the vertical axis 170 and is distributed in a substantially constant manner over the upper surface 152 of the fifth element 800. Similar to fourth element 500 described with respect to fig. 5-6, fifth element 800 may deform when fifth element 800 is subjected to the force of second load 900. In some embodiments, the deformation that occurs may be related to the location of any aperture and/or the size and orientation of the aperture.

For example, when the compressive force of the second load 900 is applied to the fifth element 800, the region including more pores and/or larger-sized pores may be deformed to a greater degree than the portion of the fifth element 800 having fewer pores and/or smaller-sized pores. Thus, any hole opening or passage may be compressed and/or deformed as a result of the application of the second load 900. In some embodiments, the buffer response may be greater in areas with holes relative to areas without holes.

For convenience, heights are associated with different portions of the fifth element 800. For example, referring to fig. 8, the seventh height 810 is associated with a third area 864, the eighth height 820 is associated with a fourth area 866, and the ninth height 830 is associated with a seventh area 872. As can be seen, in the unloaded configuration of fig. 8, seventh height 810, eighth height 820, and ninth height 830 are substantially similar such that thickness 140 is substantially uniform throughout fifth element 800.

However, as shown in FIG. 9, when fifth element 800 is subjected to a second load 900 (represented by an arrow), the arrangement of apertures 150 may change the responsiveness of the material. In fig. 9, a tenth height 910 associated with a third area 864, an eleventh height 920 associated with a fourth area 866, and a twelfth height 930 associated with a seventh area 872 can be identified.

Referring to fig. 8 and 9, the overall height of the fifth element 800 is reduced in response to the second load 900. For example, tenth height 910 is less than seventh height 810, eleventh height 920 is less than eighth height 820, and twelfth height 930 is less than ninth height 830. Comparing fig. 8 with fig. 9, it can be seen that the degree of deformation is significantly less in the areas without holes. For example, as the entire surface of fifth element 800 is compressed and the overall height of the cushioning element is reduced, various contours may be formed along upper surface 152 to which second load 900 has been applied. It can be seen that tenth height 910 is substantially different from eleventh height 920, and eleventh height 920 is different from twelfth height 930, such that thickness 140 is substantially non-uniform throughout fifth element 800. In some embodiments, these profiles may vary in a manner that generally corresponds to the arrangement of the apertures 150 provided in the fifth element 800. Thus, the eleventh height 920 associated with the region that does not include apertures is greater than the tenth height 910 and the twelfth height 930 that include apertures. This allows each zone to provide different buffering properties.

Thus, exposure to various forces may also produce changes in the shape or geometry, size, and/or height of the cushioning element and the apertures that may be disposed within the cushioning element. It should be understood that although the first load 600 and the second load 900 are shown as being substantially uniform, other loads may be non-uniform. The change in area, volume, size, and/or shape of the cushioning element may vary depending on the magnitude and direction of the force(s) applied. In some embodiments, the different forces may permit the cushioning element to expand in a lateral or longitudinal direction such that the overall length of the element is increased. In other embodiments, different forces may alter the response of the cushioning element.

It should be noted that the various degrees of deformation described and illustrated herein are for illustrative purposes. In some cases, the cushioning element may not withstand compression to the extent depicted, or may be more or less deformable, depending on various factors, such as the materials used in producing the cushioning element, and its incorporation in other objects or articles. For example, if the cushioning element is engaged or attached to a less reactive material, the compression and/or expansion characteristics described herein may be different or limited. In some embodiments, the ability to expand may be reduced when the cushioning element is engaged to strobel or other structure. In some embodiments, the perimeter of the cushioning element may be secured, for example, bonded to the strobel layer or another sole layer. However, in such embodiments, the cushioning properties of the cushioning element may still contribute to increased flexibility and cushioning.

Further, it should be understood that although fourth element 500 and fifth element 800 may be subjected to various forces and deformations, the deformations may be elastic. In other words, once the load is removed or reduced, the cushioning element may recover and return to its original size and/or shape, or to a size and/or shape substantially similar to the original unloaded configuration.

It should be understood that in some embodiments, the shape or orientation of the apertures may also vary. The change in area or shape may be different depending on the magnitude and direction of the force(s) applied. For example, in one embodiment, fourth element 500 and/or fifth element 800 may be exposed to a force or load, whereby the aperture deforms not only by becoming more compact, but also by curling or otherwise becoming more and more non-linear and/or irregular. In one embodiment, the area or volume of the aperture may increase when a compressive force is applied.

Referring to fig. 10-19, in various embodiments, a particular pattern may be selected and/or formed in the cushioning element. In some embodiments, the cushioning characteristics of the cushioning element may be modified by removing material in the cushioning element and/or drilling holes in the cushioning element to form a particular pattern. In some embodiments, a plurality of apertures may be disposed in a regular or irregular pattern along a portion of the cushioning element. In some cases, the holes may be arranged at regular intervals. For purposes of this disclosure, a regular pattern refers to a consistent (or otherwise generally invariant), repeating, geometric, periodic, stable, and/or repetitive arrangement. For example, a plurality of openings or holes arranged in a circle, ring, or other geometric shape may be regularly arranged.

In some embodiments, the apertures may be arranged along a common circumference, or extend along a common radius, to form a regular pattern. Holes positioned along or associated with the same circumference may be understood to mean that the holes are disposed at a substantially similar radial distance from the center point. For purposes of this disclosure, apertures disposed on a common or same circumference may also be understood to describe apertures disposed in a manner that forms a generally circular or curved perimeter or boundary. In various embodiments, "circumference" may be continuous or discontinuous. In other words, the boundaries of the circumference may be continuous (i.e., a solid line or uninterrupted boundary or shape) or discontinuous (i.e., a broken general boundary or shape such that the shape is implied by the arrangement of the apertures, and may be dashed, or include spaces or openings along the perimeter of the shape).

Several examples of regular patterns that may be formed in the cushioning element are depicted in fig. 10-13. It should be understood that these patterns are for illustrative purposes only, and that any other hole pattern may be formed using the principles disclosed herein. In fig. 10, a regular first pattern ("first pattern") 1000 is shown. The first pattern 1000 has a generally circular configuration that includes a series of holes 150 arranged in a repeating circular arrangement. In other words, there are multiple (hole) circumferences of different sizes in the first pattern 1000. In other embodiments, the first pattern may refer to a single circumference within a larger hole pattern.

As described above, it should be understood that the pattern depicted in the first pattern 1000 may include apertures 150 of various shapes and/or sizes. Thus, the aperture 150 may be circular or another regular or irregular shape. Further, the apertures 150 may comprise different lengths. For example, 16 holes are depicted in cross-sectional view 1050 of first pattern 1000 taken across line 10-10. In cross-sectional view 1050, first aperture 1052, second aperture 1054, third aperture 1056, fourth aperture 1058, fifth aperture 1060, sixth aperture 1062, seventh aperture 1064, eighth aperture 1066, ninth aperture 1068, tenth aperture 1070, tenth aperture 1072, twelfth aperture 1074, thirteenth aperture 1076, fourteenth aperture 1078, fifteenth aperture 1080, and sixteenth aperture 1082 are shown. It should be understood that in other embodiments, there may be a greater or lesser number of apertures included in the first pattern 1000 than shown herein.

In some embodiments, each aperture may have a length that is different from the length of an adjacent aperture, or one or more apertures may have a substantially similar length. In some cases, the holes 150 may have an oscillating or tapered length pattern. For example, in the cross-sectional view 1050 of fig. 10, it can be seen that as the holes 150 approach the center 1010 (i.e., in a radially inward direction), the lengths of the holes 150 decrease and then increase again as they move away from the center 1010 (i.e., in a radially outward direction). For purposes of this disclosure, center 1010 may refer to the approximate origin of the circumference of the depicted hole. As an illustration, in some cases, the first aperture 1052 may have a first length 1012, the third aperture 1056 may have a second length 1014, the eighth aperture 1066 may have a third length 1016, and the sixteenth aperture 1082 may have a fourth length 1018. In some embodiments, first length 1012 may be greater than second length 1014. In some embodiments, second length 1014 may be greater than third length 1016. Further, third length 1016 and/or second length 1014 may be less than fourth length 1018. In some cases, different apertures may have similar lengths. In one embodiment, the first length 1012 may be substantially similar to the fourth length 1018.

In various embodiments, "mirror image" patterns may be formed. In one embodiment, the holes disposed along the same circumference may have substantially similar lengths. In other words, the lengths of the holes disposed along the same circumference may be substantially similar to each other. Thus, in one instance, the fifth and

twelfth holes

1060 and 1074 disposed on the same circumference may include similar lengths. In some embodiments, two or more apertures disposed along a common circumference may have similar lengths. However, in other embodiments, the length of the holes may be different than shown here, may have a different repeating pattern, or may be random.

In addition, referring to fig. 10, it can be seen that each hole may be disposed at a distance from its neighboring holes. In different embodiments, the distance between the holes may be similar, or they may vary. In one embodiment, the distance between the two apertures may vary based on whether the two apertures are disposed along a common circumference (i.e., disposed at similar radial distances from the center 1010), or whether they are disposed along different circumferences.

As shown in fig. 10, in some cases, there may be two or more apertures disposed adjacent to each other but disposed on different circumferences. In cross-sectional view 1050, it can be seen that first aperture 1052 is spaced apart from second aperture 1054 by a first radial distance 1028 and seventh aperture 1064 is spaced apart from eighth aperture 1066 by a second radial distance 1030. Further, the eighth hole 1066 is spaced apart from the ninth hole 1068 by a third radial distance 1032, and the eleventh hole 1072 is spaced apart from the twelfth hole 1074 by a fourth radial distance 1034. In some embodiments, first radial distance 1028 may be similar to or different than second radial distance 1030. In fig. 10, first radial distance 1028 is substantially similar to second radial distance 1030 and fourth radial distance 1034. In other words, the apertures disposed adjacent to each other and along adjacent circumferences may be spaced apart from each other at a substantially uniform distance.

However, in some embodiments, there may be greater or lesser distances between the holes disposed on different circumferences. In some cases, some of the holes may be spaced apart from each other at irregular distances. In one example, third radial distance 1032 may be greater than first radial distance 1028, second radial distance 1030, and/or fourth radial distance 1034. In one embodiment, the third radial distance 1032 may represent a diameter of a circumference in which the eighth hole 1066 and the ninth hole 1068 are disposed. In some embodiments, third radial distance 1032 may be approximately twice first radial distance 1028. In other embodiments, third radial distance 1032 may be more than twice first radial distance 1028. In other words, a portion of the cushioning element disposed proximate the center 1010 may not include an aperture. In one embodiment, the distance between the eighth hole 1066 and the ninth hole 1068 may be a reflection of the lack of additional circumferentially disposed holes near the center 1010.

Similarly, in various embodiments, the apertures disposed adjacent to one another and sharing a common circumference may be spaced at regular or similar intervals. For example, in fig. 10, the seventeenth aperture 1084 and the eighteenth aperture 1086 are separated by a first circumferential distance 1020, and the nineteenth aperture 1088 and the twentieth aperture 1090 are separated by a second circumferential distance 1022. In some embodiments, first circumferential distance 1020 and second circumferential distance 1022 may be substantially similar, or they may be different. In fig. 10, first circumferential distance 1020 and second circumferential distance 1022 are substantially similar. Thus, in some embodiments, the apertures disposed along a common circumference may be evenly spaced from one another.

Further, the distance between adjacent holes disposed along the first circumference may be different or similar to the distance between adjacent holes disposed along the second circumference. For example, twenty-first and twenty-

second holes

1092 and 1094 disposed on a common first circumference may be separated by a third circumferential distance 1024, and twenty-third and twenty-

fourth holes

1096 and 1098 disposed on a common second circumference may be separated by a fourth circumferential distance 1026. In some embodiments, the third circumferential distance 1024 and the fourth circumferential distance 1026 may be similar. In other embodiments, the third circumferential distance 1024 and the fourth circumferential distance 1026 may be different. In fig. 10, the third circumferential distance 1024 is greater than the fourth circumferential distance 1026.

It will also be appreciated that in some cases, the circumferential distance may be close to zero or approximately zero, such that the two apertures touch or merge. For example, the twenty-fifth hole 1097 and the twenty-sixth hole 1099 on the circumference closest to the center 1010 are shown nearly touching each other. In other embodiments, the two holes may be disposed close enough to each other so as to form a substantially continuous opening similar to a cut groove. This feature will be further discussed with reference to fig. 11 and 12.

In some cases, the patterns may be formed whereby the distance between the apertures disposed along a common circumference may decrease or increase in a certain direction. For example, in the first pattern 1000, apertures disposed further radially outward from the center 1010 are spaced apart by a greater distance, while apertures disposed further radially inward toward the center 1010 are spaced apart from each other by a relatively closer distance. For example, the distance between the apertures may decrease or increase in a direction extending from the outermost perimeter 1040 to the center 1010. Thus, in one embodiment, the first circumferential distance 1020 may be greater than the third circumferential distance 1024 and the third circumferential distance 1024 may be greater than the fourth circumferential distance 1026.

In fig. 11, a regular second pattern ("second pattern") 1100 is shown. Similar to the first pattern 1000 of fig. 10, the second pattern 1100 has a generally circular configuration that includes a series of apertures 150 arranged in a repeating circular arrangement. As described above, it should be understood that the pattern depicted in the second pattern 1100 may include apertures 150 of various shapes and/or sizes. Thus, the aperture 150 may be circular or another regular or irregular shape.

Further, the apertures 150 may comprise different or similar lengths. For example, 16 holes are depicted in a cross-sectional view 1150 of the second pattern 100 taken across line 11-11. In the cross-sectional view 1150, a first aperture 1152, a second aperture 1154, a third aperture 1156, a fourth aperture 1158, a fifth aperture 1160, a sixth aperture 1162, a seventh aperture 1164, an eighth aperture 1166, a ninth aperture 1168, a tenth aperture 1170, a tenth aperture 1172, a twelfth aperture 1174, a thirteenth aperture 1176, a fourteenth aperture 1178, a fifteenth aperture 1180, and a sixteenth aperture 1182 are shown. It should be understood that in other embodiments, there may be a greater or lesser number of apertures included in the second pattern 1100 than shown herein.

In some embodiments, each aperture may have a length that is different from the length of an adjacent aperture, or one or more apertures may have a substantially similar length. In some cases, the holes 150 may have an oscillating or tapered length pattern. For example, in the cross-sectional view 1150 of fig. 11, it can be seen that as the apertures 150 approach the center 1110 (i.e., in a radially inward direction), the length of the apertures 150 increases and then decreases again as they move away from the center 1110 (i.e., radially outward). For purposes of this disclosure, center 1110 may refer to the approximate origin of the circumference of the depicted hole. As an illustration, in some cases, the first aperture 1152 can have a first length 1112, the third aperture 1156 can have a second length 1114, the eighth aperture 1166 can have a third length 1116, and the sixteenth aperture 1182 can have a fourth length 1118. In some embodiments, the first length 1112 may be less than the second length 1114. In some embodiments, second length 1114 may be less than third length 1116. Further, third length 1116 and/or second length 1114 may be greater than fourth length 1118. In some cases, different apertures may have similar lengths. In one embodiment, the first length 1112 may be substantially similar to the fourth length 1118.

In various embodiments, similar to FIG. 10, a "mirror image" pattern may be formed. In one embodiment, the holes disposed along the same circumference may have substantially similar lengths. In other words, the lengths of the holes disposed along the same circumference may be substantially similar to each other. Thus, in one instance, fifth hole 1160 and twelfth hole 1174 may have similar lengths. In some embodiments, two or more apertures disposed along a common circumference may have similar lengths. However, in other embodiments, the length of the holes may be different than shown here, may have a different repeating pattern, or may be random.

In addition, referring to fig. 11, it can be seen that each hole may be disposed at a distance from its neighboring holes. In some embodiments, the distances between the holes 150 may be similar, or they may vary. The distance between the two apertures may vary based on whether the two apertures are disposed along a common circumference (i.e., disposed at similar radial distances from the center 1110), or whether they are disposed along different circumferences.

As shown in fig. 11, in some cases, there may be two or more apertures disposed adjacent to each other but disposed on different circumferences. In cross-sectional view 1150, it can be seen that the first aperture 1152 is spaced apart from the second aperture 1154 by a first radial distance 1128, and the seventh aperture 1164 is spaced apart from the eighth aperture 1166 by a second radial distance 1130. Further, the eighth hole 1166 is spaced apart from the ninth hole 1168 by a third radial distance 1132, and the tenth hole 1170 is spaced apart from the eleventh hole 1172 by a fourth radial distance 1134. In some embodiments, first radial distance 1128 may be similar to or different than second radial distance 1130. In FIG. 11, first radial distance 1128 is substantially similar to second radial distance 1130 and fourth radial distance 1134. In other words, the holes arranged along adjacent circumferences may be spaced apart at a substantially uniform distance.

However, in some embodiments, there may be greater or lesser distances between the holes disposed on different circumferences. In some cases, such holes may be spaced apart from each other at irregular distances. In one example, third radial distance 1132 may be greater than first radial distance 1128, second radial distance 1130, and/or fourth radial distance 1134. In one embodiment, the third radial distance 1132 may represent a diameter of a circumference in which the eighth and

ninth holes

1166, 1168 are disposed. In one embodiment, third radial distance 1132 may be about twice as large as first radial distance 1128. In other embodiments, third radial distance 1132 may be more than twice as long as first radial distance 1128. In other words, a portion of the cushioning element disposed proximate the center 1110 may not include an aperture. In one embodiment, the distance between the eighth hole 1166 and the ninth hole 1168 may be greater, reflecting the lack of additional holes disposed toward the center 1110.

Further, in various embodiments, the apertures disposed adjacent to one another and sharing a common circumference may be spaced at regular or similar intervals. For example, in fig. 11, the seventeenth aperture 1184 and the eighteenth aperture 1186 are separated by a first circumferential distance 1120, and the nineteenth aperture 1188 and the twentieth aperture 1190 are separated by a second circumferential distance 1122. In some embodiments, first circumferential distance 1120 and second circumferential distance 1122 may be substantially similar, or they may be different. In fig. 11, first circumferential distance 1120 and second circumferential distance 1122 are substantially similar. Thus, in some embodiments, the apertures disposed along a common circumference may be evenly spaced from one another.

Further, the distance between adjacent holes disposed along the first circumference may be different from or similar to the distance between adjacent holes disposed along the second circumference. For example, twenty-first and twenty-

second apertures

1192 and 1194 disposed on a common first circumference may be separated by a third circumferential distance 1124, and twenty-third and twenty-

fourth apertures

1196 and 1198 disposed on a common second circumference may be separated by a fourth circumferential distance 1126. In some embodiments, third circumferential distance 1124 and fourth circumferential distance 1126 may be similar. In other embodiments, third circumferential distance 1124 and fourth circumferential distance 1126 may be different. In fig. 11, third circumferential distance 1124 is greater than fourth circumferential distance 1126.

As described above, in some embodiments, the circumferential distance between the two apertures may approach zero or about zero. In other words, the two apertures may approach, touch, and/or merge with one another. For example, the innermost circumference, including the first circumference 1181, includes a series of holes whose edges meet each other. In other words, each of the apertures of the first circumference 1181 are disposed sufficiently close to each other so as to form a substantially continuous opening similar to a cut groove. In various embodiments, this replication of the kerf may be the result of different degrees of merger between adjoining apertures. In some embodiments, holes may be formed in various portions of the cushioning element to create a cut-trench-like region, groove, or channel through the cushioning element. While this arrangement may provide variations in cushioning, there may be other benefits, including enhanced traction or grip of the exterior surface. Various designs or flexible regions may also be formed by including such grooved holes.

Furthermore, in some embodiments, the patterns may be formed such that the distance between the apertures disposed along a common circumference may decrease or increase in a certain direction. For example, in the second pattern 1100, the apertures disposed further radially outward are spaced apart at greater distances, while the apertures disposed further radially inward are spaced apart at closer distances. For example, the distance between the apertures may decrease or increase in a direction extending from the outermost perimeter 1140 to the center 1110. Thus, in one embodiment, first circumferential distance 1120 may be greater than third circumferential distance 1124, and third circumferential distance 1124 may be greater than fourth circumferential distance 1126.

In fig. 12, a regular third pattern ("third pattern") 1200 is shown. Similar to the first pattern 1000 of fig. 10 and the second pattern 1100 of fig. 11, the third pattern 1200 has a generally circular configuration that includes a series of apertures 150 disposed in a repeating circular arrangement. As described above, it should be understood that the pattern depicted in the third pattern 1200 may include apertures 150 of various shapes and/or sizes. Thus, the aperture 150 may be circular or another regular or irregular shape.

Further, the apertures 150 may comprise different lengths or have substantially similar lengths. For example, 24 holes are depicted in a cross-sectional view 1250 of the third pattern 1200 taken across line 12-12. In cross-sectional view 1250, first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, seventeenth, eighteenth, nineteenth, 1288, twentieth, 1290, twenty-first, twenty-second, 1294, twenty-fourth and 1298

holes

1252, 1254, 1266, 1270, 1282, seventeenth, 1284, 1286, 1288 are shown. It should be understood that in other embodiments, there may be a greater or lesser number of apertures disposed in the third pattern 1200 than shown herein.

In some embodiments, each aperture may have a length that is different from the length of an adjacent aperture, or one or more apertures may have a substantially similar length. In some cases, the apertures 150 may have a substantially uniform length throughout the third pattern 1200. For example, in the cross-sectional view 1250 of fig. 12, it can be seen that the length of the apertures 150 remains substantially uniform as the apertures 150 approach the center 1210 (i.e., move in a radially inward direction), and the length of the apertures 150 also remains substantially uniform as they move radially outward (away from the center 1210). For the purposes of this disclosure, center 1210 may refer to the approximate origin of the circumference of the depicted hole. By way of illustration, in some cases, the first aperture 1252 may have a first length 1212 and the twelfth aperture 1274 may have a second length 1214. In one embodiment, first length 1212 may be substantially similar to second length 1214. In other cases, all of the holes in the pattern may have substantially similar lengths. In other words, the lengths of the holes disposed along the same circumference and disposed on different circumferences may be substantially similar to each other. However, in other embodiments, the length of the holes may be different than shown here, may have a different repeating length pattern, or may have a random length arrangement.

In fig. 12, it can be seen that the holes may be spaced at varying distances from adjacent holes. The distance between the holes may vary based on whether the two holes are disposed along a common circumference (i.e., disposed at similar radial distances from the center 1210), or whether they are disposed along different circumferences.

As shown in fig. 12, in some cases, there may be two or more apertures disposed adjacent to each other but disposed on different circumferences. In cross-sectional view 1250, it can be seen that first bore 1252 is spaced apart from second bore 1254 by a first radial distance 1228, and fourth bore 1258 is spaced apart from fifth bore 1260 by a second radial distance 1230. Further, the tenth aperture 1270 is spaced apart from the eleventh aperture 1272 by a third radial distance 1232, and the twelfth aperture 1274 is spaced apart from the thirteenth aperture 1276 by a fourth radial distance 1234. In some embodiments, the first radial distance 1228 may be similar to or different than the second radial distance 1230. In fig. 12, first radial distance 1228 is substantially greater than second radial distance 1230 or third radial distance 1232. Further, second radial distance 1230 is greater than third radial distance 1232. In other words, the holes arranged along adjacent circumferences may be spaced apart at different distances.

In different embodiments, there may be a geometric pattern with respect to the spacing between the holes. In some embodiments, the distance between the holes may decrease as they approach the center 1210 (i.e., in a radially inward direction) and then increase again as they move radially outward (moving away from the center 1210). It should be understood that in other cases, the distance between the holes may increase as they approach the center 1210 (i.e., in a radially inward direction) and decrease again as they move radially outward. In one embodiment, the spacing between the holes may be mirrored. For example, the distance between two apertures may be substantially similar to the distance between two apertures disposed on opposite sides (i.e., between apertures disposed along the same two adjacent circumferences). In other words, the apertures disposed along the same two circumferences may be spaced apart from each other by substantially similar distances.

In some embodiments, there may be a larger portion of the cushioning element that does not include an aperture. For example, fourth radial distance 1234 may be greater than first radial distance 1228, second radial distance 1230, and/or third radial distance 1232. In one embodiment, the fourth radial distance 1234 may represent the diameter of the circumference in which the twelfth hole 1274 and the thirteenth hole 1276 are disposed. In one embodiment, fourth radial distance 1234 may be about twice as large as third radial distance 1232. In other embodiments, fourth radial distance 1234 may be more than twice third radial distance 1232. In other words, the center 1210 may be associated with a portion of the cushioning element that does not include an aperture. In one embodiment, the distance extending between the twelfth aperture 1274 and the thirteenth aperture 1276 may be greater since there are no additional apertures. In other embodiments, fourth radial distance 1234 may be less than or similar to first radial distance 1228, second radial distance 1230, and/or third radial distance 1232.

Further, in various embodiments, the apertures disposed adjacent to one another and sharing a common circumference may be spaced at regular or similar intervals. For example, in fig. 12, the twenty-fifth and twenty-

sixth apertures

1202, 1204 are separated by a first circumferential distance 1220, and the twenty-seventh and twenty-

eighth apertures

1206, 1208 are separated by a second circumferential distance 1222. In some embodiments, first circumferential distance 1220 and second circumferential distance 1222 may be substantially similar, or they may be different. In fig. 12, the first circumferential distance 1220 and the second circumferential distance 1222 are substantially similar. Thus, in some embodiments, the apertures disposed along a common circumference may be evenly spaced from one another.

Further, the distance between adjacent holes disposed along a first circumference may be different from or similar to the distance between adjacent holes disposed along a second, different circumference. For example, the twenty-ninth aperture 1236 and the thirty-third aperture 1238 disposed on a common first circumference may be separated by a third circumferential distance 1224 and the thirty-first aperture 1244 and the thirty-second aperture 1246 disposed on a common second circumference may be separated by a fourth circumferential distance 1226. In some embodiments, the third circumferential distance 1224 and the fourth circumferential distance 1226 may be similar. In other embodiments, the third circumferential distance 1224 and the fourth circumferential distance 1226 may be different. In fig. 12, the third circumferential distance 1224 is greater than the fourth circumferential distance 1226.

As described with respect to fig. 11, in some embodiments, the circumferential distance between two apertures may approach zero or about zero. In other words, the two apertures may approach, touch, and/or merge with one another. For example, the innermost circumference 1297 includes a series of holes whose edges contact each other. In other words, each of the holes of the innermost circumference 1297 are disposed close enough to each other to form a substantially continuous opening similar to a cut groove. In some embodiments, holes may be formed in various portions of the cushioning element to create a cut-trench-like region, groove, or channel through the cushioning element. While this arrangement may provide variations in cushioning, there may be other benefits, including enhanced traction or grip of the exterior surface. Various designs or flexible regions may be formed by including such grooved holes.

Thus, similar to the first pattern 1000 in fig. 10 and the second pattern 1100 in fig. 11, in some cases, a pattern may be formed whereby the distance between the holes disposed along the common circumference may decrease or increase in a certain direction. In one embodiment, the distance between the apertures may decrease or increase in a direction extending from the outermost perimeter 1240 to the center 1210. For example, in the third pattern 1200, the apertures disposed further radially outward are spaced apart at greater distances, while the apertures disposed further radially inward are spaced apart at closer distances. Thus, in one embodiment, the first circumferential distance 1220 may be greater than the third circumferential distance 1224, and the third circumferential distance 1224 may be greater than the fourth circumferential distance 1226.

In fig. 13, a regular fourth pattern ("fourth pattern") 1300 is shown. Similar to the first pattern 1000 of fig. 10, the second pattern 1100 of fig. 11, and the third pattern 1200 of fig. 12, the fourth pattern 1300 has a generally circular configuration that includes a series of apertures 150 disposed in a repeating circular arrangement. As described above, it should be understood that the pattern depicted in the fourth pattern 1300 may include apertures 150 of various shapes and/or sizes. Thus, the aperture 150 may be circular or another regular or irregular shape.

Further, the apertures 150 may comprise different lengths or have substantially similar lengths. For example, 24 holes are depicted in a cross-sectional view 1350 of the fourth pattern 1300 taken across line 13-13. In cross-sectional view 1350, first hole 1352, second hole 1354, third hole 1356, fourth hole 1358, fifth hole 1360, sixth hole 1362, seventh hole 1364, eighth hole 1366, ninth hole 1368, tenth hole 1370, eleventh hole 1372, twelfth hole 1374, thirteenth hole 1376, fourteenth hole 1378, fifteenth hole 1380, sixteenth hole 1382, seventeenth hole 1384, eighteenth hole 1386, nineteenth hole 1388, twentieth hole 1390, twenty-first hole 1392, twenty-second hole 1394, twenty-third hole 1396, and twenty-fourth hole 1398 are shown. It should be understood that in other embodiments, there may be a greater or lesser number of apertures disposed in the fourth pattern 1300 than shown here.

In some embodiments, each aperture may have a length that is different from the length of an adjacent aperture, or one or more apertures may have a substantially similar length. In some cases, the apertures 150 may have a substantially uniform length throughout the fourth pattern 1300. For example, in the cross-sectional view 1350 of fig. 13, it can be seen that the apertures 150 include an undulating length pattern as the apertures 150 approach the center 1310 (i.e., in a radially inward direction), and additionally as they move radially outward. For purposes of this disclosure, center 1310 may refer to the approximate origin of the circumference of the depicted hole. Illustratively, in some cases, the first aperture 1352 can have a first length 1312 and the fourth aperture 1358 can have a second length 1314. In some cases, different apertures may have different lengths. In fig. 13, the first length 1312 is substantially greater than the second length 1314. Further, third length 1316 is associated with a twelfth hole 1374. In some embodiments, the third length 1316 may be substantially similar to the second length 1314. Further, fourth length 1318 may be substantially similar to first length 1312. In other words, there may be holes having similar lengths throughout the fourth pattern 1300. In fig. 13, the apertures are configured such that the lengths (in a direction extending from the outermost perimeter 1340 toward the center 1310) of alternating apertures have similar lengths.

In other cases, all of the holes in the pattern may have substantially similar lengths. In other words, the lengths of the holes disposed along the same circumference and disposed on different circumferences may be substantially similar to each other. However, in other embodiments, the length of the holes may be different than shown here, may have a different repeating pattern, or may be random.

In fig. 13, it can be seen that each hole may be spaced apart from an adjacent hole by a distance. In some embodiments, the distance between the holes 150 may vary. The distance between the apertures may vary based on whether the two apertures are disposed along a common circumference (i.e., disposed at similar radial distances from the center 1310), or whether they are disposed along different circumferences.

As shown in fig. 13, in some cases, there may be two or more apertures disposed adjacent to each other but disposed on different circumferences. In cross-sectional view 1350, it can be seen that first hole 1352 is spaced apart from second hole 1354 by a first radial distance 1328, and third hole 1356 is spaced apart from fourth hole 1358 by a second radial distance 1330. Further, eighth hole 1366 is spaced apart from ninth hole 1368 by third radial distance 1332 and tenth hole 1370 is spaced apart from eleventh hole 1372 by fourth radial distance 1334. Further, twelfth hole 1374 is spaced apart from thirteenth hole 1376 by a fifth radial distance 1336. In some embodiments, the respective radial distances may be similar or different from one another. In fig. 13, first radial distance 1328 is substantially greater than second radial distance 1330, third radial distance 1332, or fourth radial distance 1334. Further, second radial distance 1330 is greater than third radial distance 1332 and fourth radial distance 1334. In other words, the holes arranged along adjacent circumferences may be provided at different distances from each other.

In different embodiments, there may be a geometric pattern with respect to the spacing between the holes. In some embodiments, the distance between the apertures may decrease as they approach the center 1310 (i.e., in a radially inward direction) and then increase again as they move radially outward (moving away from the center 1310). It should be appreciated that in other embodiments, the distance between the apertures may increase as they approach the center 1310 (i.e., in a radially inward direction) and then decrease again as they move radially outward. In one embodiment, the spacing between the holes may be mirrored. For example, the distance between two apertures may be substantially similar to the distance between two apertures disposed on opposite sides (i.e., between apertures disposed along the same two adjacent circumferences). In other words, the apertures disposed along the same two circumferences may be spaced apart from each other by substantially similar distances.

In some embodiments, there may be a larger portion of the cushioning element that does not include an aperture. For example, fifth radial distance 1336 may be greater than first radial distance 1328, second radial distance 1330, third radial distance 1332, and/or fourth radial distance 1334. In one embodiment, fifth radial distance 1336 may represent a diameter of a circumference in which twelfth hole 1374 and thirteenth hole 1376 are disposed. In other embodiments, fifth radial distance 1336 may be less than first radial distance 1328, second radial distance 1330, third radial distance 1332, and/or fourth radial distance 1334. In one embodiment, fifth radial distance 1336 may be about twice as large as third radial distance 1332. In other embodiments, fifth radial distance 1336 may be more than twice as great as third radial distance 1332.

Thus, in some embodiments, there may be a larger portion of the cushioning element that does not include an aperture. For example, in one embodiment, the distance extending from twelfth hole 1374 across to thirteenth hole 1376 may be greater since there are no additional holes.

In various embodiments, the holes disposed adjacent to each other sharing a common circumference may be spaced at regular or similar intervals. For example, in fig. 13, the twenty-fifth and twenty-

sixth holes

1302, 1304 are separated by a first circumferential distance 1320, and the twenty-seventh and twenty-

eighth holes

1306, 1308 are separated by a second circumferential distance 1322. In some embodiments, first circumferential distance 1320 and second circumferential distance 1322 may be substantially similar, or they may be different. In fig. 13, the first circumferential distance 1320 and the second circumferential distance 1322 are substantially similar. Thus, in some embodiments, the apertures disposed along a common circumference may be evenly spaced apart from one another.

Further, the distance between adjacent holes disposed along the first circumference may be different from or similar to the distance between adjacent holes disposed along the second circumference. For example, a twenty-ninth aperture 1337 and a thirty-third aperture 1338 disposed on a common first circumference may be separated by a third circumferential distance 1324, and a thirty-first aperture 1344 and a thirty-second aperture 1346 disposed on a common second circumference are separated by a fourth circumferential distance 1326. In some embodiments, third circumferential distance 1324 and fourth circumferential distance 1326 may be similar. In other embodiments, third circumferential distance 1324 and fourth circumferential distance 1326 may be different. In fig. 13, third circumferential distance 1324 is greater than fourth circumferential distance 1326.

Thus, similar to the regular pattern described above in fig. 10-12, in some cases, a pattern may be formed whereby the distance between the apertures disposed along a common circumference may decrease or increase in a certain direction. In one embodiment, the distance between the apertures may decrease or increase in a direction extending from the outermost perimeter 1340 to the center 1310. For example, in the fourth pattern 1300, the apertures disposed further radially outward are spaced apart at greater distances, while the apertures disposed further radially inward are spaced apart at closer distances. In one embodiment, first circumferential distance 1320 may be greater than third circumferential distance 1324, and third circumferential distance 1324 may be greater than fourth circumferential distance 1326.

In various embodiments, it should be understood that each of the circumferences described herein may include holes disposed at substantially similar radial distances from a center point. In other words, each circumferential pattern may have a plurality of apertures, and each of the plurality of apertures may be located at a substantially similar distance from a center of the circumferential pattern. Further, fig. 10 to 13 are referred to. It can be seen that when two or more circumferential patterns are disposed adjacent to one another in such a way that the first circumference uniformly defines the second circumference (i.e., each circumference shares a substantially similar center point), they can be distinguished by the difference in their respective radial distances from the center.

For example, in fig. 10, a first circumference 1081 comprising a first set of apertures is disposed in a first pattern 1000. Generally, defining the first circumference 1081 is a second circumference 1083 comprising a second set of apertures. Referring to cross-sectional view 1050, it can be appreciated that eighth hole 1066 and ninth hole 1068 are positioned along first circumference 1081. Further, a seventh aperture 1064 and a tenth aperture 1070 are positioned along the second circumference 1083. In some embodiments, each of the holes (including eighth hole 1066 and ninth hole 1068) making up the first circumference 1081 may be disposed at a first radial distance 1087 from the center 1010. Further, in some embodiments, each of the apertures (seventh aperture 1064 and tenth aperture 1070) making up the second circumference 1083 may be disposed at a second radial distance 1085 from the center 1010. Since the center 1010 serves as a reference point, in this case, the first radial distance 1087 and the second radial distance 1085 may be understood to refer to the approximate radius of each circle. As shown in fig. 10, in some embodiments, first radial distance 1087 may be less than second radial distance 1085. In other words, each of the holes making up the first circumference 1081 may be disposed closer to the center 1010 than each of the holes making up the second circumference 1083. Further, in one embodiment, each of the holes making up the first circumference 1081 may be disposed at substantially the same radial distance from the center 1010. In another embodiment, each of the holes making up the second circumference 1083 may be disposed at substantially the same radial distance from the center 1010.

Similarly, in fig. 11, a first circle 1181 comprising a first set of apertures is disposed in the second pattern 1100. Generally, defining the first circumference 1181 is a second circumference 1183 comprising a second set of apertures. Referring to the cross-sectional view 1150, it can be appreciated that the eighth aperture 1166 and the ninth aperture 1168 are positioned along a first circumference 1181. Further, a seventh hole 1164 and a tenth hole 1170 are positioned along a second circumference 1183. In some embodiments, each of the apertures (including the eighth aperture 1166 and the ninth aperture 1168) making up the first circumference 1181 may be disposed at a first radial distance 1187 from the center 1110. Further, in some embodiments, each of the apertures (seventh aperture 1164 and tenth aperture 1170) making up the second circumference 1183 may be disposed at a second radial distance 1185 from the center 1110. Since the center 1110 serves as a reference point, the first radial distance 1187 and the second radial distance 1185 may be understood to refer to the approximate radius of each circle in this case. As shown in fig. 11, in some embodiments, the first radial distance 1187 may be less than the second radial distance 1185. In other words, each of the apertures making up the first circumference 1181 may be disposed closer to the center 1110 than each of the apertures making up the second circumference 1183. Further, in one embodiment, each of the apertures making up the first circumference 1181 may be disposed at substantially the same radial distance from the center 1110. In another embodiment, each of the apertures making up the second circumference 1183 may be disposed at substantially the same radial distance from the center 1110.

Referring to fig. 12, a first circumference 1281 including a first set of apertures is disposed in the third pattern 1200. Generally, defining first circumference 1281 is a second circumference 1283 that includes a second set of apertures. Referring to the cross-sectional view 1250, it can be appreciated that the twelfth aperture 1274 and the thirteenth aperture 1276 are positioned along the first circumference 1281. Further, an eleventh aperture 1272 and a fourteenth aperture 1278 are positioned along the second circumference 1283. In some embodiments, each of the holes making up the first circumference 1281 (including the twelfth hole 1274 and the thirteenth hole 1276) may be disposed at a first radial distance 1287 from the center 1210. Since the center 1210 serves as a reference point, in this case, the first radial distance 1287 and the second radial distance 1285 may be understood to refer to an approximate radius of each circumference. Further, in some embodiments, each of the holes making up the second circumference 1283 (including the eleventh hole 1272 and the fourteenth hole 1278) may be disposed at a second radial distance 1285 from the center 1210. As shown in fig. 12, in some embodiments, first radial distance 1287 may be less than second radial distance 1285. In other words, each of the holes making up the first circumference 1281 may be disposed closer to the center 1210 than each of the holes making up the second circumference 1283. Further, in one embodiment, each of the holes making up the first circumference 1281 may be disposed at substantially the same radial distance from the center 1210. In another embodiment, each of the holes making up the second circumference 1283 may be disposed at substantially the same radial distance from the center 1210.

Likewise, in fig. 13, a first circumference 1381 comprising a first set of apertures is disposed in the fourth pattern 1300. Generally, defining the first circumference 1381 is a second circumference 1383 comprising a second set of apertures. Referring to cross-sectional view 1350, it can be appreciated that twelfth holes 1374 and thirteenth holes 1376 are positioned along a first circumference 1381. Further, eleventh and fourteenth apertures 1372, 1378 are positioned along a second circumference 1383. In some embodiments, each of the holes (including the twelfth hole 1374 and the thirteenth hole 1376) that make up the first circumference 1381 may be disposed at a first radial distance 1387 from the center 1310. Further, in some embodiments, each of the holes making up the second circumference 1383 (including the eleventh hole 1372 and the fourteenth hole 1378) may be disposed at a second radial distance 1385 from the center 1310. Since center 1310 is used as a reference point, first radial distance 1387 and second radial distance 1385 may be understood to refer to the approximate radius of each circle in this case. As shown in fig. 13, in some embodiments, the first radial distance 1387 may be less than the second radial distance 1385. In other words, each of the apertures comprising the first circumference 1381 may be disposed closer to the center 1310 than each of the apertures comprising the second circumference 1383. Further, in one embodiment, each of the apertures making up the first circumference 1381 may be disposed at substantially the same radial distance from the center 1310. In another embodiment, each of the apertures making up the second circumference 1383 may be disposed at substantially the same radial distance from the center 1310.

In various embodiments, each of the circumferential arrangements of holes included in the pattern may be similarly disposed throughout the pattern. Thus, each circumference of the holes in the first pattern 1000, the second pattern 1100, the third pattern 1200, and/or the fourth pattern 1300 may include a series of holes, each hole disposed at a substantially similar radial distance from the center of the pattern.

As described above, in various embodiments, a particular pattern may be selected and/or formed in the cushioning element. In other embodiments, a plurality of apertures may be used and disposed in a regular or irregular pattern along a portion of the cushioning element. In some embodiments, the holes may be arranged at irregular intervals. For the purposes of this disclosure, an irregular pattern refers to a generally inconsistent (or otherwise substantially varying, non-repeating, or random) arrangement of apertures. For example, the plurality of openings provided in a substantially random pattern or an irregular shape may be irregularly arranged. It should be understood that some patterns may include regular patterns and irregular patterns.

Several examples of irregular patterns that may be formed are depicted in fig. 14-19. It should be understood that these patterns are for illustration purposes only and that any other pattern may be formed using the principles disclosed herein. In fig. 14 to 18, an irregular fifth pattern ("fifth pattern") 1400 is shown. It should be understood that in other embodiments, there may be a greater or lesser number of apertures disposed in the fifth pattern 1400 than shown herein. Additionally, as described above, it should be understood that the pattern depicted in the fifth pattern 1400 may include apertures 150 of various shapes and/or sizes. Thus, the aperture 150 may be circular or another regular or irregular shape. Further, as described with reference to fig. 10-13, the apertures 150 may include different lengths or have substantially similar lengths throughout the fifth pattern 1400.

In different embodiments, the apertures in the pattern may be arranged to form various smaller aperture configurations and subsets. In some embodiments, the apertures 150 may be arranged in a manner to form one or more curved configurations. In one embodiment, the apertures 150 may be disposed along a generally semi-circular shape, thereby forming a semi-circular arrangement. Referring to fig. 14-18, in some cases, one or more semi-circular holes, hereinafter referred to as "semi-circles," may be disposed about the center 1410. In some embodiments, one or more semi-circular patterns may be used.

To better illustrate various arrangements of the apertures 150 of the fifth pattern 1400, a sequence of diagrams highlighting various portions of the fifth pattern 1400 is depicted in fig. 14-18. For the purposes of this disclosure, the term "highlighted" refers to some apertures that are described as darker relative to the non-highlighted apertures in the illustration. Thus, the differences in the darkness or shading of the apertures shown in fig. 14-18 during discussion should not be considered as necessarily distinguishing the apertures, except to identify particular regions for reference purposes. To further facilitate identification of a particular hole arrangement, a curve may be drawn over a portion of the semi-circle to emphasize the defined arrangement.

In fig. 14, a first semicircle 1402 and a second semicircle 1404 are highlighted. Similar to the discussion above regarding the circumference, the apertures disposed along the common semi-circle may be aligned or disposed in a manner that forms a generally circular or curved portion of the boundary. In some embodiments, holes described as being positioned along the same semi-circle may be understood to mean that the holes are disposed at a similar or nearly similar radial distance from the center 1410. In some cases, the boundary may be a solid line, or the boundary may be a dashed line, or include a gap or opening.

In fig. 15, two additional semicircles are highlighted, including a third semicircle 1502 and a fourth semicircle 1504 disposed radially adjacent to the first semicircle 1402 and the second semicircle 1404. For purposes of this disclosure, "radially adjacent" refers to an arrangement of elements or apertures disposed adjacent to one another but having substantially different radial distances from the center 1410. For example, the apertures of first semicircle 1402 are disposed at an average first radial distance 1510 from center 1410, and the apertures of third semicircle 1502 are disposed at an average second radial distance 1520 from center 1410. In some embodiments, first radial distance 1510 and second radial distance 1520 may be different. In fig. 14 and 15, first radial distance 1510 is less than second radial distance 1520. In other embodiments, first radial distance 1510 may be greater than or equal to second radial distance 1520.

Further, in some embodiments, radially adjacent semi-circles may be arranged in a staggered or rotated configuration relative to each other. In the embodiment of fig. 14-18, for example, the first and

fourth semicircles

1402, 1504 are staggered with respect to one another. The degree of staggering or rotation may vary in different embodiments. For example, in some embodiments, the semi-circles or other hole arrangements may form an angle of less than 90 degrees and greater than 0 degrees with respect to each other. In other embodiments, the semi-circles or other arrangements of holes may form an angle of 90 degrees or more with respect to each other. In fig. 15, it can be seen that the first semicircle 1402 and the fourth semicircle 1504 are staggered by about 90 degrees. However, in other embodiments, radially adjacent semi-circles may be provided in a stacked configuration such that the hole arrangements are substantially aligned with each other (see the repeated circumferences of fig. 10-13).

In fig. 16, 12 additional semicircles are highlighted, including a fifth semicircle 1602, a sixth semicircle 1604, a seventh semicircle 1606, an eighth semicircle 1608, a ninth semicircle 1610, a tenth semicircle 1612, a tenth semicircle 1614, a twelfth semicircle 1616, a thirteenth semicircle 1618, a fourteenth semicircle 1620, a fifteenth semicircle 1622, and a sixteenth semicircle 1624. In some embodiments, the semi-circles may be arranged such that they form a pattern with each other relative to the center 1410. In one example, the apertures of the seventh semicircle 1606 are disposed at an average third radial distance 1630 from the center 1410, and the apertures of the eighth semicircle 1608 are disposed at an average fourth radial distance 1640 from the center 1410. In some embodiments, third radial distance 1630 and fourth radial distance 1640 may be substantially similar. In other words, seventh semicircle 1606 and eighth semicircle 1608 may be arranged to create a pattern along a common circumference. In one embodiment, seventh semicircle 1606 and eighth semicircle 1608 may be disposed in a mirror image orientation with respect to center 1410. However, in other embodiments, seventh semicircle 1606 and eighth semicircle 1608 may be disposed in any position along cushioning elements. In another embodiment, three or more semi-circles may be oriented in a repeating pattern around the center 1410. For example, the thirteenth, fourteenth, fifteenth and

sixteenth semicircles

1618, 1620, 1622, 1624 may be arranged in a quarter pattern such that the thirteenth semicircle 1618 is disposed opposite (mirror image of) the sixteenth semicircle 1624 and the fourteenth semicircle 1620 is disposed opposite (mirror image of) the fifteenth semicircle 1622.

Further, in some embodiments, the holes in the irregular pattern may form different shapes. For example, in FIG. 17, eight additional semi-circles are highlighted, as well as the first circle 1702. In some embodiments, a substantially discontinuous or continuous shape may be formed, as shown in fig. 10-13. In fig. 17, the first circle 1702 includes holes arranged to create a discontinuous boundary around the center 1410, similar to the arrangement of holes in a circle described with reference to fig. 10-13.

In fig. 18, additional apertures arranged in various curved or non-linear configurations have been highlighted, including a first outer curve 1802 and a second outer curve 1804. It should be understood that in different embodiments, the apertures may form part shapes or boundaries that are oriented differently than the semi-circles described thus far. For example, in fig. 18, the first outer curve 1802 includes a plurality of curved regions of the aperture. Some of the curved regions may be different from other regions, as shown in a first curve 1806 and a second curve 1808, each curve including a different arrangement of holes.

Referring again to fig. 14-18, in various embodiments, the holes disposed adjacent to each other sharing a common semicircle may be spaced at varying intervals or distances. For example, in fig. 14, the apertures disposed along the first semicircle 1402 are closely arranged such that they contact or touch each other. Thus, the circumferential distance may be about zero. In other words, each of the apertures of the first semicircle 1402 is disposed close enough to each other to form a substantially continuous opening similar to a cut groove. In another example, the first circumferential distance 1020 between the seventeenth aperture 1084 and the eighteenth aperture 1086 of fig. 10 may be about zero such that a continuous aperture is formed.

In various embodiments, the replication of the kerf may be the result of different degrees of merger between adjoining apertures. In some embodiments, holes may be formed in various portions of the cushioning element to create a cut-trench-like region, groove, or channel through the cushioning element. While this arrangement may provide variations in cushioning, there may be other benefits, including enhanced traction or grip of the exterior surface. Various designs or flexible regions may be formed by including such grooved holes.

However, in other embodiments, the distance between adjacent holes disposed along the same semicircle may be different. In one embodiment, referring to the first circle 1702 in FIG. 17, it can be seen that while some of the holes are in contact with each other (thereby creating a merge region), other holes in the first circle 1702 are spaced apart from each other. For example, the first circle 1702 includes a first pair of holes and a second pair of holes. The holes of the first pair are spaced apart from each other by a first distance 1701 and the holes of the second pair are disposed at a second distance from each other. In some embodiments, the first distance 1701 may be different from the second distance 1703. In fig. 17, the first distance 1701 is less than the second distance 1703. In other embodiments, the first distance 1701 may be greater than or equal to the second distance 1703.

Thus, different pairs of holes disposed along a common semi-circle may be arranged at varying or irregular distances relative to each other. Similarly, the distance between holes disposed along different semicircles may vary. For example, referring to fig. 15, the apertures of the third semicircle 1502 are disposed further than the apertures of the first semicircle 1402.

Another embodiment of a possible irregular pattern of holes is depicted in fig. 19. In fig. 19, a sixth pattern 1900 is shown that includes a plurality of aperture rows 1950. The rows of apertures 1950 may extend various distances across the sixth pattern 1900 and may include any of the features, characteristics, and/or configurations described above with reference to fig. 10-18. In fig. 19, the sixth pattern 1900 includes a first row 1902, a second row 1904, a third row 1906, and a fourth row 1908. As shown in fig. 19, in some cases, the apertures may be arranged to have a substantially linear configuration or design.

In different embodiments, the rows of apertures 1950 can be arranged in various configurations relative to each other. In some embodiments, as depicted in fig. 19, two or more rows of apertures 1950 can be substantially parallel to each other. In other embodiments, the rows 1950 of holes may be arranged at different angles relative to each other.

Further, adjacent rows of apertures 1950 can be arranged at different distances from each other. For example, there may be an average first distance 1910 between the first row 1902 and the second row 1904, and an average second distance 1912 between the third row 1906 and the fourth row 1908. In some embodiments, as shown in fig. 19, the first distance 1910 may be greater than the second distance 1912. In other embodiments, the first distance 1910 may be less than or equal to the second distance 1912.

It should be understood that each semicircle or hole arrangement may include a different number of holes. Referring to fig. 14 and 16, for example, the first semicircle 1402 includes 12 holes and the ninth semicircle 1610 includes 14 holes. In another example, in the embodiment of fig. 19, the first row 1902 includes eight apertures, the second row 1904 includes 14 apertures, and the third row 1906 includes 15 apertures. The number of apertures may be adjusted to produce varying shapes in the sixth pattern 1900. In fig. 19, a sixth pattern 1900 has an approximate (substantially) circular shape or contour. In other embodiments, the number of apertures in any of these arrangement types may be different, to include more or fewer apertures than depicted again, and/or to approximate any other shape, such as square, oval, elliptical, diamond, rectangular, triangular, star, pentagonal, or any other regular or irregular shape.

As noted above, the cushioning elements described herein may be used with various components or articles. For example, the degree of elasticity, cushioning, and flexibility of a sole member, such as a sole member, may be important factors associated with the comfort and injury prevention of an article of footwear. Fig. 20-23 depict an embodiment of a method of designing a customized sole member for an article of footwear.

Fig. 20 illustrates the three-dimensional shape of the plantar surface 2002 of the foot 2000 measured using a data collection device 2028. In some cases, the data collection device 2028 may be a force platform. In other cases, the data collection device 2028 can include one of the commercially available systems for measuring plantar pressure (e.g., an emerd sensor platform, a padar insole system, an F-Scan system, a Musgrave footprint system, etc.). Plantar pressure measurement systems may provide a means to obtain specific information about the foot that may be used to customize footwear for an individual. In some embodiments, the magnitude of the pressure may be determined by dividing the measured force by the known area of the sensor or sensors that is caused when the foot is in contact with the support surface in some embodiments.

For reference purposes, foot 2000, a representation of foot 2000, components associated with foot 2000 (such as an article of footwear, an upper, a sole member, computer-aided design of foot 2000, and other components/representations) may be divided into different regions. Foot 2000 may include forefoot region 2004, midfoot region 2006, and heel region 2008. Forefoot region 2004 may generally be associated with the toes and the joints connecting the metatarsals with the phalanges. The midfoot region 2006 may generally be associated with the metatarsals of the foot. Heel region 2008 may generally be associated with the heel of a foot that includes the calcaneus bone. In addition, foot 2000 may include a lateral side 2010 and a medial side 2012. Specifically, lateral side 2010 and medial side 2012 may be associated with opposite sides of foot 2000. In addition, lateral side 2010 and medial side 2012 may both extend through forefoot region 2004, midfoot region 2006, and heel region 2008. It should be understood that forefoot region 2004, midfoot region 2006, and heel region 2008 are for descriptive purposes only and are not intended to demarcate precise areas of foot 2000. Likewise, lateral side 2010 and medial side 2012 are intended to generally represent both sides of foot 2000 rather than precisely divide foot 2000 into two halves.

Further, in the example depicted in fig. 20 and 21, foot 2000 and/or virtual sweep 2100 of the foot may include a medial arch region 2020 associated with an upward curve along medial side 2012 of midfoot region 2006, and a lateral arch region 2022 associated with an upward curve along lateral side 2010 of midfoot region 2006. Fig. 21 best illustrates the area corresponding to lateral arch region 2022, and fig. 21 illustrates a computer screen or virtual image of digitized three-dimensional foot data. As described below, the curvature of medial arch region 2020 and lateral arch region 2022 may vary from one foot to the other. In addition, foot 2000 includes a transverse arch 2024, which transverse arch 2024 extends along plantar surface 2002 in a direction generally aligned with lateral axis 190 proximate forefoot region 2004. Foot 2000 also includes heel lobe 2026, which is the lobe located in heel region 2008 of foot 2000. As shown in fig. 20, foot 2000 is shown as the left foot; however, it should be understood that the following description may apply equally to a mirror image of the foot (or, in other words, the right foot).

Although the embodiments described throughout this detailed description depict components configured for use with an article of athletic footwear, in other embodiments, the components may be configured for use with various other types of footwear, including, but not limited to: hiking boots, soccer shoes, football shoes, athletic shoes, running shoes, cross-training shoes, football shoes, basketball shoes, baseball shoes, and other types of shoes. Further, in some embodiments, the components may be configured for use in a variety of non-athletic related footwear, including but not limited to: slippers, sandals, high-heeled shoes, happy shoes, and any other kind of footwear.

The components associated with an article of footwear are often manufactured to fit feet of various sizes. In the illustrated embodiment, the various articles are configured with substantially the same footwear size. In various embodiments, the components may be configured with any footwear size, including any conventional size for footwear known in the art. In some embodiments, the article of footwear may be designed to fit a child's foot. In other embodiments, the article of footwear may be designed to fit an adult foot. However, in other embodiments, the article of footwear may be designed to fit the feet of a man or woman.

Referring to fig. 20 and 21, the first step of the method is to collect data relating to the foot 2000 from the foot measured on the data collection device 2028, such as using light foot pressure measurements or other data. The data collection device 2028 may include provisions for capturing information about the individual's feet. In particular, in some embodiments, the data collection device 2028 may include provisions for capturing geometric information about one or more feet. The geometric information may include dimensions (e.g., length, width, and/or height) corresponding to a customer's foot, as well as three-dimensional information (e.g., forefoot geometry, midfoot geometry, heel geometry, and ankle geometry). In at least one embodiment, the captured geometric information for the customer's foot may be used to generate a three-dimensional model of the foot for a subsequent manufacturing stage. Specifically, the customized foot information may include at least a width and a length of the foot. In some cases, the customized foot information may include information about three-dimensional foot geometry. The customized foot information may be used to generate a three-dimensional model of the foot. Embodiments may include any other arrangement for capturing customized foot information. This embodiment may utilize any of the methods and systems for forming an upper disclosed in Bruce's U.S. patent No. ________ entitled Portable Manufacturing System for Articles of Footwear (U.S. patent application No.14/565,582, now filed 12/10 2014), which is hereby incorporated by reference in its entirety.

Some embodiments may use any system, Apparatus, and method for Imaging a Foot, disclosed in U.S. patent publication No.2013/0258085 entitled "Foot Imaging and Measurement Apparatus" (U.S. patent application No.13/433,463, previously filed 3/29/2012) by Leedy et al, the entire contents of which are incorporated herein by reference.

In fig. 21, screen 2102 displays a virtual scan 2100 of a plantar pressure distribution of the foot of fig. 20. Virtual scan 2100 may provide a measured foot image or representation that includes various different areas to indicate the pressure that foot 2000 is applying or experiencing on its plantar surface 2002, as shown in fig. 20. In one example, the pressures may include a first pressure zone 2104, a second pressure zone 2106, a third pressure zone 2108, a fourth pressure zone 2110, and a fifth pressure zone 2112. Additional pressure zones 2114 are indicated where the plantar surface 2002 is not in susceptible contact with the surface of the data collection device 2028. In some embodiments, colors (not shown in fig. 21) may be included in virtual scan 2100 to more easily distinguish changes within the measured pressure data. It should be noted that in other embodiments, different, fewer, or more pressure zones may be measured or indicated.

As shown in FIG. 21, in some embodiments, the collected data may include a virtual scan 2100 of foot 2000. In some embodiments, virtual scan 2100 may be used to evaluate three-dimensional shapes and obtain digital data in a two-dimensional or three-dimensional reference frame. In other embodiments, virtual scan 2100 may provide a baseline shape for the footwear component. In one embodiment, a three-dimensional scan image may be used to measure the overall shape of a person's foot and obtain two-dimensional measurements such as the contour, length, and width of foot 2000. In one embodiment, obtaining the foot geometry may establish a baseline record for the person. In some embodiments, other inputs may also be provided to supplement the information about the person being measured. In various embodiments, additional data such as toe height information may also be obtained. In other embodiments, a plaster model of a person's foot may be taken and digitized. In addition, other digital or imaging techniques that may be used to capture two-dimensional and three-dimensional foot shapes and contours may be used to construct and/or supplement virtual scan 2100. In other embodiments, the person whose feet are being measured may provide answers to questions describing the person's physical characteristics, limitations, preferences, and/or personal lifestyle, which may affect the design of the various parts described herein.

In various embodiments, the sole member may provide one or more functions for the article of footwear. In fig. 22, an image of the template of the sole member 2200 is displayed on a screen 2202. In some embodiments, sole member 2200 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running, or other ambulatory activities. In different embodiments, the configuration of the sole member 2200 may vary significantly to include a variety of conventional or non-conventional structures. In some cases, the configuration of the sole member 2200 may be selected or customized depending on the type or types of ground surfaces on which the sole member 2200 may be used. Examples of the ground include, but are not limited to: natural turf, synthetic turf, dirt, and other surfaces.

After obtaining measurements of foot 2000 (see fig. 20), sole member 2200 may be adjusted or changed in various embodiments. As shown in the virtual representation depicted in fig. 23, using the data collected from the above steps, a first customized sole 2300 may be designed. In some embodiments, the design may utilize an application of integrated computer-aided design, such as a computer-automated manufacturing (CAD-CAM) process. The sole member 2200, or any other template previously selected, may be provided as input to a computer design program. In one embodiment, three-dimensional foot shape data from virtual scan 2100 in FIG. 21 is also provided to the program.

In various embodiments, virtual scan 2100 may provide information regarding foot shape and pressure to allow for proper fit and comfort within an article of footwear. This information may be used to form first customized sole 2300. In some embodiments, data from the virtual scan 2100 may be superimposed or otherwise incorporated into a template of the sole member 2200 (see fig. 21 and 22). For example, there may be a process of registering data representing the plantar pressure of foot 2000 with sole member 2200 and producing a partial or complete design of first customized sole 2300. In one embodiment, the pressure contour 2306 may be created during the design of the first customized sole 2300. In some embodiments, the pressure profile may be adjusted to a "best fit" position based on user input. When the distribution is complete, an elastic profile may be generated. For the purposes of this disclosure, an elasticity profile is a personalized pressure profile for a user, which may include data collected during the above-described steps. In some embodiments, the elasticity profile may be used to produce first customized sole 2300. Accordingly, in one embodiment, a customized sole member may be formed or manufactured after an elastic profile including a plantar pressure distribution of an individual is registered with a template of the sole member 2200.

It should be understood that the design of the sole member may include various modifications in different embodiments. Customized modifications may provide a wider range of comfort and fit for individual users. For example, different users may vary in the height of the arch of foot 2000. As described above, foot 2000 may include multiple arches. Generally, the arch is a convex curve on the bottom surface of foot 2000. When the tendons of foot 2000 stretch a normal amount, foot 2000 typically forms a moderate or normal arch. However, when the tendons are not properly stretched together, there may be little or no arch. This is known as "flat foot" or inverted arch. Over pronation of the foot may be common to persons with flattened feet. The frame of the foot may collapse, flattening out the foot and adding stress to other portions of the foot. Individuals with flat feet may require an orthotic to control the flattening of the foot. In addition, the opposite may occur, but a high arch is less common than a flat foot. Without adequate support, a highly arched foot tends to be painful because more stress is placed on the segment of the foot between the ankle and the toes. This situation makes it difficult to fit into an article of footwear. Individuals with high arch often require foot supports. It should be noted that this variation in arch height is one of many possible examples of customized foot geometries that may be incorporated into the design.

Referring to fig. 24, an embodiment of an impact graph 2400 is depicted. Impact map 2400 reflects some of the factors or variables that may be considered, combined, and/or used during the generation of the elasticity profile, thereby permitting customization of the cushioning characteristics 2450 of the sole member. For example, the first factor 2410 includes a measured plantar pressure of each foot of the individual, as discussed above with reference to fig. 20-21. Further, second factor 2420 may include the material that will be used to form the customized sole member. The third factor 2430 may be an individual user's own personal preferences regarding the type or level of buffering desired. A fourth factor 2440 may be an activity or motion that a user would normally engage in when using the customized sole member. In some cases, the sole member may be designed or customized to provide particular cushioning in particular areas or regions of the sole member that are typically subjected to more force or pressure from the foot during particular activities. Thus, in some embodiments, one or more of these factors may contribute to the cushioning characteristics 2450 of the sole member. It should be appreciated that impact graph 2400 is provided as an example, and that many other factors not listed here may be included in other embodiments. Further, depending on the desired output or goal of the customized sole member, one or more factors listed in influence graph 2400 may be excluded from consideration.

Once the design has been created, the sole member can be manufactured as with first customized sole 2300. In some embodiments, the modification may include areas of the sole member having apertures 150 disposed along different portions of the sole member. In some embodiments, the sole member may be molded in a manner that creates apertures in the sole member. The article of footwear including the apertures may be formed in any manner. In some embodiments, any known cutting or drilling method may be used to create the holes in the sole member. For example, in one embodiment, the holes may be created using laser cutting techniques. In particular, in some cases, a laser may be used to remove material from the sole member in a manner that forms apertures in the sole member. In another embodiment, the apertures may be formed in the sole member using a hot knife process. An example of a method for forming an aperture in a Sole member is disclosed in U.S. patent No.7,607,241 to McDonald, entitled "Article of Footwear with an Articulated Sole Structure" (previously U.S. patent application No.11/869,604 filed on 9.10.2007), published on 27.10.2009, the entire contents of which are incorporated herein by reference.

However, in other embodiments, any other type of cutting method may be used to form the holes. Further, in some cases, two or more different techniques may be used to form the holes. As an example, in another embodiment, laser cutting may be used to form apertures disposed on the side surfaces of the sole member, while apertures on the lower surface of the sole member may be formed during the molding process. Still further, depending on the material used for the sole member, different types of techniques may be used. For example, laser cutting may be used where the sole member is made of a foam material.

In fig. 25, a diagram depicting an embodiment of a method of forming a first customized sole 2300 that includes an aperture is shown. Referring to fig. 25, the hole 150 may be applied to or formed in the first customized sole 2300 using a laser drill 2500. In one embodiment, the laser drill 2500 can be used to cut or remove material through the thickness 140 of the first customized sole 2300. In other cases, a greater number of laser drills may be used. In FIG. 25, a third set of apertures 2530 are formed along forefoot region 2004 along a surface of first customized sole 2300. The first set of holes 2510 in the heel region 2008 and the second set of holes 2520 in the midfoot region 2006 are shown as having been previously formed by a laser drill 2500. As an example, the first set of apertures 2510 comprises an arrangement substantially similar to the second pattern 1100 of fig. 11, and the second set of apertures 2520 comprises an arrangement substantially similar to the third pattern 1200 of fig. 12. Further, the third set of apertures 2530 includes an arrangement substantially similar to the fourth pattern 1300 of fig. 13.

Although only holes in one general area are shown to be drilled in this example, it should be understood that a similar method may be used to create or form holes in any other area of first customized sole 2300. It should also be understood that the laser drilling machine 2500 may include provisions for moving in different directions in order to direct the laser beam to a desired location. Further, the sole member may be provided such that it may be automatically or manually moved to receive laser light 2570 at an appropriate or desired location, such as along forefoot region 2004, midfoot region 2006, and/or heel region 2008. Further, while only one laser drill 2500 is shown in use in fig. 25, in other embodiments, two, three, four, or more laser drills may be engaged with the sole member.

In some embodiments, referring to enlarged region 2550, it can be seen that laser 2570 can contact upper surface 152 of first customized sole 2300. When the laser 2570 contacts the material, it may begin to remove the material and form the aperture 2522. As the laser 2570 continues to engage the material of the sole member, the aperture 2522 may grow through the thickness 140 and form the first hole 2560.

It is recalled that each hole may be formed such that they differ from each other in one or more respects, or they may be formed in a uniform manner such that they are substantially similar in size, length and shape. Further, it should be understood that laser 2500 may be oriented at an angle different than that shown in fig. 25, such that laser 2500 may form an aperture 150 oriented in a diagonal or non-parallel manner with respect to vertical axis 170, longitudinal axis 180, and/or lateral axis 190.

Thus, as described herein, in some embodiments, the arrangement of apertures on a sole member may be varied to adjust the properties of the sole member for particular types of physical or personal characteristics and/or athletic activities, and to provide particular localized cushioning characteristics. For example, in some cases, the arrangement of apertures on the sole member may be selected according to the type of activity for which the article of footwear is intended. In some embodiments, manufacturers may vary the arrangement of apertures for various types of footwear, including, but not limited to, soccer shoes, running shoes, cross-training shoes, basketball shoes, and other types of footwear. Additionally, in other embodiments, the arrangement of apertures on the sole member may vary depending on the gender of the intended user. For example, in some cases, the hole arrangement may vary between men's shoes and women's shoes. Still further, in some embodiments, the arrangement of apertures on the sole member may be varied according to user preferences to achieve desired performance effects. By way of example, the need to increase flexibility on the lateral side of the article may be accommodated by increasing the number and/or size of apertures on the lateral side of the sole member. Further, in some embodiments, the configuration of the apertures on the sole may be changed to achieve various visual or graphical effects. Further, as discussed above, the placement of the apertures may be individually customized by measuring various pressure areas of the person's foot and applying this information to the location and type of apertures on the sole member.

It should be appreciated that the method of customizing the hole configuration for a particular sport, gender, and/or personal preference may be implemented in any manner. In one embodiment, a method of customizing an aperture configuration of an article may include provisions for allowing a user to select a customized aperture arrangement by interacting with a website that provides customization tools for varying the number and/or geometry of various apertures. Examples of different customization systems that can be used to customize the aperture configuration are disclosed in the following patent publications: U.S. patent publication No.2005/0071242 to Allen et al entitled "Method and System for Custom Footwear" (previously filed on 30/9/2003) published on 31/3/2005 (U.S. patent application No.10/675,237); U.S. patent publication No.2004/0024645 to Potter et al, entitled "Custom made Footwear for Sale (Custom Fit salt of Footwear)" published on 5.2.2004 (previously U.S. patent application No.10/099,685 filed on 14.3.2002), the entire contents of which are incorporated herein by reference. It should be appreciated that the method of customizing the aperture arrangement of an article of footwear is not limited to use with any particular customization system, and generally any type of customization system known in the art may be used.

The articles of the embodiments discussed herein may be made from materials known in the art for use in the manufacture of articles of footwear. For example, the sole member may be made of any suitable material, including but not limited to: elastomers, silicones, natural rubber, other synthetic rubbers, aluminum, steel, natural leather, synthetic leather, foams, or plastics. In exemplary embodiments, the materials used for the sole member may be selected to enhance the overall flexibility, fit, and stability of the article. In one embodiment, a foam material may be used with the sole member, as the foam may provide the desired resiliency and strength. In another embodiment, a rubber material may be used to make the midsole of the sole member. In another embodiment, a thermoplastic material may be used with the sole member. For example, in one embodiment, Thermoplastic Polyurethane (TPU) may be used to make the midsole of the sole member. In other embodiments, the sole member may include a multi-density insert that includes at least two regions of different densities. For example, in another embodiment, a midsole of a sole member may be configured to receive one or more inserts. An example of a different type of insert that may be used is disclosed in U.S. patent No.7,941,938 entitled "Footwear with Lightweight Sole Assembly (Article of Footwear with a light weight Sole Assembly)" issued on 5/17 2011 (previously U.S. patent application No.11/752,348 filed on 23/3/2007), the entire contents of which are incorporated herein by reference. Additionally, the upper may be made from any suitable material known in the art, including, but not limited to: nylon, natural leather, synthetic leather, natural rubber, or synthetic rubber.

An article of footwear may include provisions for adjusting the flexibility characteristics of a sole member having a plurality of apertures. In some embodiments, different materials may be used with different portions of the sole. In exemplary embodiments, portions of the sole may be filled with additional materials or components to provide different types of cushioning, feel, and flexibility to the sole member. For example, in one embodiment, the core portion of the sole member may include a fluid-filled member, such as a bladder. In another embodiment, one or more portions of the sole member may include a hollow cavity that is capable of receiving a fluid or other material.

An article of footwear may include provisions for adjusting the flexibility characteristics of a sole structure having a plurality of apertures. In some embodiments, different materials may be used with different portions of the sole. In exemplary embodiments, portions of the sole may be filled with additional materials or components to provide different types of cushioning, feel, and flexibility to the sole structure. For example, in one embodiment, the core portion of the sole structure may include a fluid-filled member, such as a bladder. In another embodiment, one or more portions of the sole structure may include a hollow cavity that is capable of receiving a fluid or other material.

FIG. 26 illustrates another embodiment of a customized sole member for an article of footwear. In fig. 26, article of footwear 2600 is shown, referred to herein as article 2600. Article 2600 may be configured as any type of footwear, including, but not limited to: hiking boots, soccer shoes, ball shoes, athletic shoes, football shoes, basketball shoes, baseball shoes, and other types of footwear. Article 2600 may include an upper 2602 and a sole structure 2610. Sole structure 2610 is secured to upper 2602 and extends between the foot and the ground when article 2600 is worn. In different embodiments, sole structure 2610 may include different components. For example, sole structure 2610 may include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional.

In general, the customized sole member may include any layer or element of sole structure 2610 and be configured as desired. In particular, the layers of the sole structure may have any design, shape, size, and/or color. For example, in embodiments in which the article of footwear is a basketball shoe, the sole member may include contours shaped to provide greater support to the heel lobe. In embodiments where the article of footwear is a running shoe, the customized sole member may be configured with a profile that supports forefoot region 2004. In some embodiments, sole structure 2610 may further include provisions for fastening to an upper or another sole layer, and may also include other provisions found in footwear sole members. In addition, some embodiments of sole structure 2610 may include other materials disposed within the customized sole member, such as bladders, leather, synthetic materials (such as plastic or synthetic leather), mesh, foam, or combinations thereof.

The materials selected for sole structure 2610 or components of sole structure 2610 may have sufficient durability to withstand the repeated compression and bending forces generated during running or other athletic activities. In some embodiments, the material(s) may comprise foam; polymers such as polyurethane or nylon; a resin; metals such as aluminum, titanium, stainless steel or light weight alloys; or a composite combining carbon or glass fibers with a polymeric material, ABS plastic, PLA, glass filled polyamide, a light curable material (epoxy), silver, titanium, steel, wax, photopolymer and polycarbonate. The customized sole member may also be formed from a single material or a combination of different materials. For example, one side of the customized sole member may be formed of a polymer while the opposite side may be formed of foam. Further, particular regions may be formed of different materials depending on the expected forces experienced by each region.

In fig. 26, a bottom isometric view of upper 2602 (in phantom) with sole structure 2610 is shown, where sole structure 2610 includes a second customized sole 2650. Upper surface 2652 is disposed on an upper side of second customized sole 2650 and lower surface 2654 is disposed on a bottom side (i.e., the side that will face the ground and/or outsole when worn by a user). Upper surface 2652 and lower surface 2654 together comprise an exterior surface of second customized sole 2650. Apertures 150 are provided along various portions of the exterior surface, with apertures 150 extending a varying length and including a varying pattern through thickness 140 of second customized sole 2650.

In some embodiments, apertures 150 may be provided on both upper surface 2652 and lower surface 2654 of second customized sole 2650. In other embodiments, apertures 150 may be provided on only one surface of second customized sole 2650. In fig. 26, the aperture 150 is formed along the lower surface 2654. The seventh pattern 2670 is visible in the heel region 2008 and the eighth pattern 2680 is visible in the middle in a portion of the forefoot region 2004. As an example, the seventh pattern 2670 includes an arrangement substantially similar to the sixth pattern 1900 of fig. 19, and the eighth pattern 2680 includes an arrangement substantially similar to the fifth pattern 1400 of fig. 14. In other embodiments, any other regular or irregular pattern may be included in second customized sole 2650. Further, any of the hole patterns described herein may be enlarged or contracted (i.e., such that the size of each hole in the pattern increases or decreases proportionally) to include different sized patterns in the sole member. In other words, in some embodiments, the sole member may include a portion of a single pattern that is enlarged to extend over the entire sole member. In another embodiment, the size of the individual patterns may be reduced to correspond to the large toe area of the sole member. In other embodiments, any pattern may be re-sized to be formed along any portion of the sole member. In one embodiment, any of the patterns may be only partially formed on the sole member.

As described above, the apertures 150 may be arranged to correspond to and/or support the contours of the plantar surface 2002 of the foot 2000 (as described above with reference to fig. 20-23). Accordingly, second customized sole 2650 may provide general cushioning throughout forefoot region 2004 and heel region 2008, as well as more specialized cushioning in regions where apertures are provided in a particular arrangement (as previously described).

Accordingly, various cushioning elements as described herein may provide a customized sole structure having a specific response to ground reaction forces. In one embodiment, the cushioning element may attenuate and distribute ground reaction forces. For example, apertures provided in the cushioning element may help attenuate ground reaction forces when a portion of the customized sole structure contacts the ground. The cushioning element may have the ability to distribute ground reaction forces throughout a substantial portion of the customized sole structure. The attenuating nature of this type of structure may reduce the degree to which ground reaction forces may affect the foot, and the distributing nature distributes the ground reaction forces to various portions of the foot. In some embodiments, these features may reduce peak ground reaction forces experienced by the foot.

In other embodiments, the cushioning element designs disclosed in this specification may also include provisions for achieving non-uniform ground reaction force distribution. For example, customizing the ground reaction force distribution of the sole structure may provide the wearer with a response similar to barefoot running but with a reduced ground reaction force. That is, the customized sole structure may be designed to impart a barefoot running feel, but with a reduced ground reaction force level. Furthermore, in another example, ground reaction forces may be more concentrated in the medial side of the foot than along the lateral side of the foot, thereby reducing the likelihood that the foot will over-pronate, or imparting greater resistance to eversion and inversion of the foot.

In some embodiments, the use of a cushioning element in an orthosis for an article of footwear may help support the weakened area of the foot and assist the user in each step. While relatively rigid materials, as may be included in a custom sole structure, may provide functional support for the foot, the softer or more flexible regions associated with apertures 150 may absorb loads placed on the foot and provide protection. Such softer or cushioned regions may better absorb loads placed on the foot, increase stability, and remove pressure from uncomfortable or painful points of the foot.

Other embodiments or variations of the customized sole structure may include other lattice structure designs or various combinations of the above disclosed designs. It should be noted that the present description is not limited to cushioning elements having the geometry or aperture configuration of first customized sole 2300 or second customized sole 2650. In various embodiments, each customized sole structure may include additional variations not depicted in the figures. Some variations may include differences in shape, size, contour, height, concavity, curvature, and other variations. In other words, the customized sole structures depicted herein are intended only to provide examples of the many types of cushioning element-based sole structure configurations that fall within the scope of the present discussion.

An embodiment of a sole member production process as described herein is summarized in the flowchart of FIG. 27. In a first step 2710, a pressure distribution of the user's foot is obtained (see fig. 20 to 23 above). In other words, a pressure profile associated with the left and/or right foot (i.e., the first and second feet) of the user may be obtained. The pressure profile, as well as any other preferences, are collected to generate an elasticity profile. In a second step 2720, the elastic profile may be used to create a customized configuration or pattern of apertures (e.g., location, size, length, orientation, etc.) in the sole member. In some embodiments, the particular configuration of the resulting aperture may be stored in virtual or digital form. It should be understood that in some embodiments, a first pattern of holes may be created for the left foot, and a second pattern of holes may be created for the corresponding right foot. After creating the one or more hole patterns, instructions for forming holes in the sole member may be prepared or generated in a third step 2730. In some cases, the hole pattern may be converted into a series of commands or instructions that the system follows in order to convert the hole pattern into mechanical or design steps for forming a customized sole member. Finally, in a fourth step 2740, the instructions are executed and a customized sole member is produced. In some embodiments, the instructions are executable to produce a first customized sole member (e.g., for a left foot) and a complementary second customized sole member (e.g., for a right foot).

In some embodiments, the processes described herein can occur in rapid succession and in close proximity to one another. However, in other embodiments, one or more steps may occur at intervals in time and location. In other words, one step may occur at a first location and another step may occur at a second location, where the first location is different from the second location. For example, the elasticity profile of the first step 2710 may be generated off-site (e.g., at a shopping mall or clinic, etc.), and the hole pattern of the second step 2720 may be generated in a manufacturing facility. In another example, instructions for forming the apertures of third step 2730 may be prepared or generated locally, while the actual production of the customized sole member of fourth step 2740 may occur at a remote location (e.g., out of state or abroad).

In various embodiments, any other method known in the art may be used to form the sole members discussed herein and any apertures in the sole members. In some embodiments, one or more apertures (e.g., aperture 150) may be formed using any removal process (i.e., where a portion of the material is removed, subtracted, eliminated, etc.). For example, in some embodiments, mechanical processes may be used, including but not limited to: ultrasonic machining, water jet machining, abrasive water jet machining, ice jet machining, and/or magnetic grinding. In other embodiments, chemical processes may be utilized, including but not limited to: chemical milling, photochemical milling, and/or electropolishing. Further, in some embodiments, an electrochemical process may be used. In other embodiments, thermal processes, such as Electrical Discharge Machining (EDM), laser beam machining, electron beam machining, plasma beam machining, and/or ion beam machining, or other processes may be used. In another embodiment, a hybrid electrochemical process may be utilized, including but not limited to: electrochemical grinding, electrochemical honing, electrochemical superfinishing, and/or electrochemical polishing. In addition, hybrid thermal processes, such as electroerosion dissolution machining, may be used. In other embodiments, the material comprising the sole member may be modified using a chemical process, including a temperature change (e.g., a frozen material). Further, the process for forming the apertures may be applied or utilized after the article of footwear has been assembled, or where the sole member has been associated with an upper or sole structure. In other words, the formation of the apertures in the sole member may occur after post-manufacture of the article of footwear.

It should be understood that in other embodiments, the midsole may include a shell in molded foam. In other words, embodiments of sole members as described herein may be associated with a midsole of a sole structure. Accordingly, in some embodiments, the midsole may include a foam material. The foam material may include a "skin" surface formed by a molding process. In some embodiments, the various removal processes described above (e.g., drilling, laser, chemical, EDM, water cutting, etc.) may be applied to the foam skin of the midsole, and the holes may be formed in a manner similar to the embodiments discussed above.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Although many possible combinations of features are shown in the drawings and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any embodiment may be used in combination with or instead of any other feature or element in any other embodiment unless specifically limited. Thus, it should be understood that any features shown and/or discussed in this disclosure may be implemented together in any suitable combination. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Furthermore, various modifications and changes may be made within the scope of the appended claims.

Claims

1. A sole structure for an article of footwear, comprising:

a sole member including an outer surface, the outer surface including an upper surface and a lower surface;

the sole member having an interior portion, wherein the interior portion is disposed between the upper surface and the lower surface;

the sole member includes at least a first set of apertures, wherein at least one of the apertures of the first set of apertures is a blind aperture;

wherein the first set of apertures are disposed along a portion of the outer surface of the sole member;

wherein each aperture of the first set of apertures has a length that extends through a portion of the interior portion of the sole member; and

wherein the first set of apertures includes more than 100 apertures formed as a plurality of apertures rings, wherein each aperture ring of the first set of apertures is arranged in a circular first pattern around a first center along the outer surface of the sole member, wherein the plurality of aperture rings includes: (a) a first eyelet at a first radial distance from the first center, the first eyelet having a first length into the sole member; and (b) a second eyelet located at a second radial distance from the first center, the second eyelet having a second length into the sole member, wherein the first radial distance is different than the second radial distance, and wherein the first length is different than the second length.

2. The sole structure of claim 1, wherein the first set of apertures includes a first aperture, wherein the first aperture has a circular cross-sectional shape.

3. The sole structure of claim 1, wherein the first set of apertures includes a first aperture, wherein the first aperture is oriented in a vertical direction, and wherein the vertical direction extends between the upper surface and the lower surface.

4. The sole structure of claim 1, wherein the sole member further includes a second set of apertures, wherein the second set of apertures is disposed along a portion of the outer surface of the sole member, wherein each aperture of the second set of apertures has a length that extends through a portion of the interior portion of the sole member, wherein the second set of apertures is arranged in a second pattern of circles along the outer surface of the sole member, and wherein the second pattern of circles is spaced apart from the first pattern of circles.

5. The sole structure according to claim 4, wherein the first center is located in a heel region of the sole member, and wherein the circular second pattern has a second center located in a midfoot region of the sole member.

6. The sole structure according to claim 4, wherein the first center is located in a heel region of the sole member, and wherein the circular second pattern has a second center located in a forefoot region of the sole member.

7. The sole structure of claim 4, wherein the sole member further includes a third set of apertures, wherein the third set of apertures is disposed along a portion of the outer surface of the sole member, wherein each aperture of the third set of apertures has a length that extends through a portion of the interior portion of the sole member, wherein the third set of apertures is arranged in a third pattern of circles along the outer surface of the sole member, and wherein the third pattern of circles is spaced apart from the first pattern of circles and is spaced apart from the second pattern of circles.

8. A sole structure according to claim 7, wherein the first center is located in a heel region of the sole member, wherein the circular second pattern has a second center located in a midfoot region of the sole member, and wherein the circular third pattern has a third center located in a forefoot region of the sole member.

9. The sole structure of claim 4, wherein the second set of apertures includes more than 100 apertures.

10. The sole structure of claim 1, wherein the first set of apertures are located in a heel region of the sole member.

11. The sole structure of claim 1, wherein the first set of apertures are located in a midfoot region of the sole member.

12. A sole structure for an article of footwear, comprising:

the sole member having at least a first set of apertures, wherein at least one of the first set of apertures is a blind aperture;

wherein the first set of apertures includes more than 100 apertures formed as a plurality of apertures rings, wherein each aperture ring of the first set of apertures is disposed along a portion of the outer surface of the sole member to form a circular first pattern about a first center, wherein the plurality of aperture rings includes:

(a) a first ring of holes, wherein each hole of the first ring of holes is disposed at a first radial distance from the first center, and

(b) a second ring of holes, wherein each hole of the second ring of holes is disposed at a second radial distance from the first center, wherein the first radial distance is different from the second radial distance.

13. The sole structure of claim 12, wherein each aperture of the first set of apertures has a circular cross-sectional shape.

14. The sole structure of claim 12, wherein the sole member further includes a second set of apertures, wherein the second set of apertures are disposed in a circular second pattern along a portion of the outer surface of the sole member, and wherein the circular first pattern is spaced apart from the circular second pattern.

15. The sole structure according to claim 14, wherein the first center is located in a heel region of the sole member, and wherein the circular second pattern has a second center located in a midfoot region of the sole member.

16. The sole structure according to claim 14, wherein the first center is located in a heel region of the sole member, and wherein the circular second pattern has a second center located in a forefoot region of the sole member.

17. The sole structure of claim 14, wherein the sole member further includes a third set of apertures, wherein the third set of apertures is disposed along a portion of the outer surface of the sole member, wherein the third set of apertures is arranged in a circular third pattern along the outer surface of the sole member, and wherein the circular third pattern is spaced apart from the circular first pattern and spaced apart from the circular second pattern.

18. A sole structure according to claim 17, wherein the first center is located in a heel region of the sole member, wherein the circular second pattern has a second center located in a midfoot region of the sole member, and wherein the circular third pattern has a third center located in a forefoot region of the sole member.

19. The sole structure according to claim 14, wherein the first pattern of rounded shapes is disposed along a forefoot region of the sole member, and wherein the second pattern of rounded shapes is disposed along a heel region of the sole member.

20. The sole structure of claim 12, wherein at least one aperture of the first set of apertures is oriented in a diagonal direction with respect to the upper surface.

21. The sole structure according to claim 12, wherein the sole member includes cushioning properties, and wherein the cushioning properties of the sole member vary with the number of apertures formed in the sole member.

22. A method of customizing a cushioning sole system for an article of footwear, the method comprising:

obtaining information about a pressure distribution of a foot of a wearer;

generating a pattern for a sole member, wherein the pattern for a sole member comprises a first set of apertures, wherein the first set of apertures comprises more than 100 apertures formed as a plurality of aperture rings, wherein each aperture ring of the first set of apertures is disposed along a portion of an outer surface of the sole member to form a circular first pattern about a first center, wherein the plurality of aperture rings comprises: (a) a first ring of holes, wherein each hole of the first ring of holes is disposed at a first radial distance from the first center; and (b) a second ring of holes, wherein each hole of the second ring of holes is disposed at a second radial distance from the first center, wherein the first radial distance is different from the second radial distance;

generating instructions to form the pattern for a sole member in the sole member; and

executing the instructions to form the first set of apertures in the sole member.

23. The method according to claim 22, further comprising obtaining information regarding the wearer's preferences regarding cushioning of the article of footwear, and wherein the first pattern of apertures is customized according to the received information regarding the wearer's preferences regarding the cushioning of the article of footwear.

24. The method of claim 22, further comprising forming a hole in the sole member using a laser.

25. The method of claim 22, further comprising generating an elasticity profile comprising data representing a personalized pressure profile for the wearer.

26. The method of claim 22, wherein the first and second portions are selected from the group consisting of,

wherein the step of creating the pattern for the sole member further comprises providing a second set of apertures in a circular second pattern along a portion of the outer surface of the sole member, and wherein the circular first pattern is spaced apart from the circular second pattern; and

wherein the step of executing the instructions further comprises forming the second set of apertures in the sole member.